System and method for recovering inert feedstock contaminants from municipal solid waste during gasification

ABSTRACT

A multi-stage product gas generation system converts a carbonaceous material, such as municipal solid waste, into a product gas which may subsequently be converted into a liquid fuel or other material. One or more reactors containing bed material may be used to conduct reactions to effect the conversions. Unreacted inert feedstock contaminants present in the carbonaceous material may be separated from bed material using a portion of the product gas. A heat transfer medium collecting heat from a reaction in one stage may be applied as a reactant input in another, earlier stage.

RELATED APPLICATIONS

This is a Divisional of U.S. patent application Ser. No. 16/086,365,filed Sep. 19, 2018, now U.S. patent Ser. No. ______, which is a 371National Phase of International Application No. PCT/US2016/024248 filed25 Mar. 2016 and published in English as WO 2017/164888A1 on 28 Sep.2017. The contents of the aforementioned application are incorporated byreference in their entirety.

TECHNICAL FIELD

The present disclosure relates to the field of thermochemical conversionof carbonaceous materials.

BACKGROUND

The world reliance on petroleum and natural gas has reached an era wherethe supply and demand have become critical. These circumstances make theneed for innovative energy and environmental technologies essential tomediate climate change, reduce greenhouse gas emissions, reduce air andwater pollution, promote economic development, expand energy supplyoptions, increase energy security, decrease U.S. dependence on importedoil, and strengthen rural economies. It is now essential that energyconversion systems and processes be introduced and commercialized thatcan employ alternative sources of energy in an environmentally benignmanner at economic costs, and can transform abundant carbonaceousmaterial resources into clean, affordable, and domestically-producedrenewable fuels and high-value products.

New technology is needed in order to exploit alternative sources ofenergy and feedstock for sustainable economic development in an energyefficient manner while maintaining a clean and unpolluted environment.The needed technologies must be sufficiently flexible, thermallyefficient, energy integrated, environmentally clean and cost effectiveto enable the use of abundant carbonaceous materials for the productionof clean and cost effective energy. Further, decreasing world reservesand diminishing availability of crude oil have created considerableincentive for the development and use of alternative fuels. In recentyears, the ever increasing value of fossil hydrocarbon liquids and gaseshas directed research, development, deployment, and commercialization tothe possibilities of employing carbonaceous materials for fuel purposes.In particular, attention has been focused on thermochemical conversionof carbonaceous materials.

Reaction vessels containing a fluidized bed of bed material are wellsuited to effectuate thermochemical processes to convert carbonaceousmaterials into product gases. A fluidized bed is formed when a quantityof a particulate bed material is placed under appropriate conditions ina reactor vessel to cause a bed material to behave as a fluid. This isusually achieved by the introduction of pressurized steam, carbondioxide, oxygen-containing gas, and/or any other gases, or vapors, toflow through the particulate bed material. This results in the bedmaterial then having many properties and characteristics of normalfluids.

Converting a carbonaceous material, such as municipal solid waste (MSW),into a product gas by the use of a fluidized bed reactor poses anexceptionally difficult challenge. This is inherently due to the inertcontaminants that are present within the MSW. MSW, commonly known astrash or garbage in the United States is a waste type comprised ofeveryday items that are discarded by the public. Inert contaminantscannot be converted into product gas, however other portions of a MSWcarbonaceous material can be converted into product gas. Instead, theMSW inert contaminants build-up and accumulate within the quantity ofbed material contained within the reactor thus inhibiting andundermining the ability of the reactor to effectuate appropriatefluidization of bed material for any thermochemical process to takeplace at all.

In applying the classification of gas/solid systems according to Geldart(D. Geldart, Powder Techn. 7, 285-293, 1973), if a fluidized bedcontains mostly easily fluidized Geldart Group B bed material,fluidization will diminish if Geldart Group D solids (inertcontaminants) accumulate within the fluidized bed. Geldart Group Dsolids may be the inert feedstock contaminants that are introduced withthe MSW. Or the Geldart Group D solids may be generated throughagglomeration of Geldart Group A or Geldart Group B solids. Nonetheless,a fluidized bed of a mean bed particle characteristic of Geldart Group Bsolids may become defluidized by buildup or accumulation ofcomparatively larger, coarser and/or heavier Geldart Group D solids thatare introduced to the fluidized bed from an external source, such aswith MSW. Defluidization may also be caused by predictable agglomerationor growth of one or more types of Geldart solids groups fusing orbinding or growing together to form larger Geldart solids groups.

Defluidization may be caused by unpredictable and unavoidable buildup oflarger Geldart particles, in comparison to the mean bed particlecharacteristic, introduced to the fluidized bed. The accumulation ofGeldart Group D solids in a fluidized bed having a mean bed particlecharacteristic of Geldart Group B solids often results in defluidized orstagnant zones in the fluidized bed and in turn demanding an increase influidization velocity to maintain fluidization quality.

Often times when a carbonaceous material feedstock possessing silicon,potassium, chloride, sodium and/or alkali earth metals within the ash,the softening or melting temperatures of these compounds may be lessthan the operating temperature of the thermochemical reactionenvironment. And as a result, the growth and accumulation ofagglomerates within the fluidized bed transitions from properfluidization to possible economically detrimental defluidization leadingto unscheduled process termination and shut down.

Various different methods of agglomeration have been described inscientific literature. Specifically, Pietsch, W. Size Enlargement byAgglomeration (New York: John Wiley & Sons, 1991) puts forth variousdifferent binding methods of agglomeration. Perhaps the most significanttypes of binding mechanisms relevant to fluidized bed agglomeration inapplications for generation of product gas from carbonaceous materialspossessing elevated silicon, potassium, chloride, sodium and/or alkaliearth metals within the ash are solid bridges such as mineral bridges,sinter bridges, chemical reaction, partial melting, hardening binders,crystallization or deposition of suspended colloidal particles. Further,agglomeration may be compounded by the presence of any of the aforesaidbinding mechanisms together with interlocking of two or more fluidizedbed particulates together thus eventually increasing the mean particlesize of the bed leading to defluidization.

Removal of accumulation of agglomerates, or removal of accumulation oflarger size Geldart type solids, in comparison to the fluidized bed meanbed Geldart particle group, and introduced to the fluidized bed from anexternal source, in many applications is impossible to do in-situ. Inmany instances, buildup of larger Geldart solid classifications within afluidized reaction environment of lesser sized Geldart solids, sayaccumulation of Geldart D solids in a fluidized bed environment ofGeldart type B solids, requires process interruption and periodictermination of operation for cleaning.

Fluidized beds typically usually have a mean bed particle characteristicof Geldart Group B solids, generally with no overlap of Geldart Group Aor Geldart Group D solids. It is therefore desirable to be able toremove Geldart Group D solids which may accumulate within the fluidizedbed of Geldart Group B solids to maintain continuous operation of thefluidized bed. Further, some fluidized bed systems have a mean bedparticle characteristic of Geldart Group A solids, generally with nooverlap of Geldart Group B or Geldart Group D solids. It is alsotherefore desirable to be able to remove any Geldart Group B or GeldartGroup D solids which may accumulate within the fluidized bed of mostlyGeldart Group A solids to maintain continuous operation of the fluidizedbed. Therefore, a need exists for a new fluidized bed process that isbetter suited to operate on a continuous and uninterrupted basis byaccommodating size and density classification of smaller type Geldartsolids for recycle back to the fluidized bed while removing solids ofcomparatively larger Geldart type from the system.

SUMMARY

Herein disclosed are innovative and advanced systems and methods relatedto the thermochemical conversion of carbonaceous materials into productgas, renewable fuels, energy products such as electricity and chemicals,the systems comprising: a three-stage energy integrated product gasgeneration system and at least one system selected from feedstockpreparation system, feedstock delivery system, particulateclassification system, primary gas clean-up system, compression system,secondary gas clean-up system, synthesis system, upgrading system andpower generation system.

More specifically, the present disclosure provides for thermallyintegrated thermochemical reaction systems and processes for theconversion of carbonaceous materials into product gas. Morespecifically, the present disclosure relates to thermally integratedsuccessive endothermic and downstream exothermic thermochemicalreactions and processes for the thermochemical conversion ofcarbonaceous material feedstock into product gas. Still morespecifically, the present disclosure relates to a first reactor being influid communication with a heat exchanger in thermal contact with adownstream reactor operating in an exothermic mode to provide reactantfor the endothermic reaction taking place within the first reactor.Still more specifically, the disclosed systems and methods are suitablefor the production of product gas for use in a refinery superstructurefor converting carbonaceous materials into renewable fuels and otheruseful chemical compounds, including gasoline, diesel, jet fuel,ethanol, alcohols, and power.

This disclosure further relates to methods for employing an energyintegrated three-stage thermochemical product gas generation systemdesigned to efficiently convert carbonaceous materials into a widespectrum of resources and added-value products including clean energyand chemical products. Some embodiments place emphasis on advancementsin the art of thermochemical reaction systems that employ endothermicand downstream exothermic reaction environments to share energy andgenerate a product gas. It is, therefore, an object of the presentdisclosure to utilize systems and methods for a first reactor being influid communication with a heat exchanger in thermal contact with asecond reactor operating in an exothermic mode to provide reactant foran endothermic reaction taking place within the first reactor. It is,therefore, an object of the present disclosure to utilize systems andmethods for a first reactor being in fluid communication with a heatexchanger in thermal contact with a downstream primary gas clean-upsystem. A primary gas clean-up heat exchanger is configured to removeheat from at least a portion of the product gas generated in the firstreactor or second reactor and to provide a heat transfer medium for usein the second reactor heat exchanger in thermal contact with a secondreactor operating in an exothermic mode to in turn provide reactant foran endothermic reaction taking place within the first reactor.

It is further an embodiment of the present disclosure to provide athree-stage product gas generation system configured to produce aproduct gas from a carbonaceous material, the system comprising a firstreactor, a second reactor, and a third reactor, a heat exchanger inthermal contact with the second reactor, and a heat exchanger in thermalcontact with the third reactor.

The first reactor has a first interior, a first reactor carbonaceousmaterial input, a first reactor reactant input, and a first reactorproduct gas output. The second reactor has a second interior, and a charinput in fluid communication with the first reactor product gas output.The second reactor also has an oxygen-containing gas input, a secondreactor product gas output, and a second reactor heat exchanger inthermal contact with its interior. The third reactor has a thirdinterior, and a combined product gas input in fluid communication withboth the first reactor product gas output and the second reactor productgas output. The third reactor also has an oxygen-containing gas input, athird reactor product gas output, and a third reactor heat exchanger inthermal contact with its interior. A portion of the heat transfer mediumused in the third reactor heat exchanger is used as the heat transfermedium in the second reactor heat exchanger. A portion of the heatedsecond reactor heat transfer medium is used as a reactant in the firstreactor and second reactor. A portion of the third reactor heat transfermedium is used as the reactant in the second reactor. And a portion ofthe third reactor heat transfer medium is used as the reactant in thefirst reactor.

It an object of the present disclosure to utilize systems and methods toconvert carbonaceous materials into product gas using a three-stageenergy integrated product gas generation system including a firstreactor, a first solids separation device, a second reactor, a secondreactor heat exchanger, a third reactor, and a third reactor heatexchanger. The second reactor heat exchanger is configured to transferheat from the second reactor to a second reactor heat transfer mediumfor use as a reactant in the first reactor or the second reactor. Thethird reactor heat exchanger is configured to transfer heat from thethird reactor to a third reactor heat transfer medium. A portion of thethird reactor heat transfer medium is sent to the inlet of the secondreactor heat exchanger to be used as a second reactor heat transfermedium. In embodiments, a first reactor is configured to receiveparticulate heat transfer material present in the interior of thedownstream reactor.

In embodiments, the first reactor is configured to receive steam as areactant so as to operate in an endothermic mode. In embodiments, thefirst reactor is configured to receive carbon dioxide as a reactant soas to operate in an endothermic mode. In embodiments, the first reactoris configured to receive an oxygen-containing gas so as to operate in anexothermic mode. In embodiments, the first reactor is configured toreceive steam and an oxygen-containing gas so as to operate in anendothermic and exothermic mode. In embodiments, the first reactor isconfigured to receive steam, oxygen-containing gas, and carbon dioxideso as to operate in an endothermic and exothermic mode.

In embodiments, the first reactor is equipped with a heat exchanger inthermal contact with the first interior of the first reactor toeffectuate an endothermic reaction. In embodiments, an auxiliary heatexchanger is configured to transfer heat from a combustion stream to anauxiliary heat exchanger heat transfer medium for use as a reactant inthe first reactor. In embodiments, an auxiliary heat exchanger heattransfer medium outlet conduit is in fluid communication with the secondreactor heat transfer medium inlet, to thereby supply the auxiliary heatexchanger heat transfer medium to the second reactor heat exchanger. Inembodiments, the inlet of the second reactor heat exchanger is in fluidcommunication with the outlet of the third reactor heat exchanger. Inembodiments, a steam turbine may be positioned between the outlet of thethird reactor heat exchanger and the inlet of the second reactor heatexchanger.

In embodiments, at least a portion of the heat transfer medium of thesecond reactor heat exchanger may be introduced into any combination ofbed material zones found in either the first reactor or in the secondrector. In this regard, the first and second reactors can each beconsidered to have a dense bend zone formed in the lower portion of thebed region, a feed zone formed in a middle portion of the bed region,and a splash zone formed in the upper portion of the bed region,immediately below the freeboard region of the reactor. It is understoodthat within the bed material, the dense bed zone is located below boththe feed and splash zones, the splash zone is located above both thedense bed zone and the feed zone, and the feed zone is located betweenthe dense bed zone and the splash zone. It is further understood thatfor present purposes, the boundary between the dense bed zone and thefeed zone is the lowest point at which carbonaceous material such asMSW, char, or any other feedstock, is introduced into a reactor.

In embodiments, a first reactor is equipped with a dense bed zone, feedzone, and splash zone, along with the first reactor carbonaceousmaterial input valves, sensors, and controllers. In embodiments,multiple carbonaceous material inputs and multiple feed zonesteam/oxygen inputs are positioned in the first reactor feed zone alongwith multiple splash zone steam/oxygen inputs positioned in the splashzone. In embodiments, various geometric first reactor feed zonecross-sectional views are elaborated upon such as circular or crosssectional views. In embodiments, only two of the six first reactorcarbonaceous material inputs are configured to inject carbonaceousmaterial into vertically extending quadrants. In embodiments, at leasttwo carbonaceous material inputs are introduced to the interior of thefirst reactor at different planes at different vertical heights aboutthe first reactor.

In embodiments, a second reactor is equipped with a dense bed zone, feedzone, and splash zone, along with a first solids separation device,second solids separation device, solids flow regulator, riser, dipleg,and valves, sensors, and controllers. In embodiments, a second reactorfeed zone cross-section includes: one first solids separation device;four second reactor first char inputs; and four feed zone steam/oxygeninputs; wherein the combined reactor product gas conduit is configuredto blend the first reactor product gas with the second reactor productgas. In embodiments, the first reactor product gas is not combined withthe second reactor product gas. In embodiments, a second reactor feedzone cross-section includes: two first solids separation devices; twosolids flow regulators; four second reactor first char inputs; four feedzone steam/oxygen inputs; and, where the combined reactor product gasconduit is configured to blend the first reactor product gas with thesecond reactor product gas.

In embodiments, particulate heat transfer material may be transferredfrom the interior of the second reactor to the interior of the firstreactor. In embodiments, the separated char may be reacted with steam inthe second reactor to produce a second reactor product gas. Inembodiments, at least a portion of the heat transfer medium may be usedas the reactant in the second reactor. In embodiments, the carbonaceousmaterial may also be reacted with an oxygen-containing gas to produce afirst reactor product gas containing char. In embodiments, a fuel sourcemay be combusted in a first reactor heat exchanger to form a combustionstream, said combustion stream indirectly heating the particulate heattransfer material in the first reactor. In embodiments, the secondreactor operated at a pressure greater than the first reactor. Inembodiments, the reaction between the carbonaceous material and steam inthe first reactor is promoted by use of a particulate heat transfermaterial.

In embodiments, this disclosure relates to a three-stageenergy-integrated product gas generation system configured to produce aproduct gas from a carbonaceous material, the system comprising: a firstreactor having a first interior and comprising: a first reactorcarbonaceous material input to the first interior; a first reactorreactant input to the first interior, and a first reactor product gasoutput; a second reactor having a second interior and comprising: asecond reactor char input to the second interior, in fluid communicationwith the first reactor product gas output; a second reactoroxygen-containing gas input to the second interior; a second reactorproduct gas output; and a second reactor heat exchanger in thermalcontact with the second interior, the second reactor heat exchangercomprising a second reactor heat transfer medium inlet and a secondreactor heat transfer medium outlet, the second reactor heat transfermedium outlet being in fluid communication with the first reactorreactant input; and, a third reactor having a third interior andcomprising: one or more product gas inputs to the third interior, influid communication with the first and second product gas outputs; athird reactor oxygen-containing gas input to the third interior; a thirdreactor product gas output; and a third reactor heat exchanger inthermal contact with the third interior, the third reactor heatexchanger comprising a third reactor heat transfer medium inlet and athird reactor heat transfer medium outlet, the third heat transfermedium outlet being in fluid communication with the second reactor heattransfer medium inlet;

wherein: the third reactor heat exchanger is configured to receive aheat transfer medium at a third reactor inlet temperature via the thirdreactor heat transfer medium inlet; and a first portion of the heattransfer medium passes through the third reactor heat exchanger and thenthe second reactor heat exchanger before being introduced, into thefirst interior via the first reactor reactant input, as a reactant at afirst reactor reactant temperature, the first reactor reactanttemperature being higher than the third reactor inlet temperature.

In embodiments, a second reactor reactant input to the second interior;wherein: the second reactor reactant input is in fluid communicationwith the second reactor heat transfer medium outlet and is configured tointroduce at least a portion of said heat transfer medium into thesecond interior as a reactant of the second reactor. In embodiments, afirst reactor oxygen-containing gas input is made available to the firstinterior and is configured to receive a first reactor oxygen-containinggas.

In embodiments, the three-stage energy-integrated product gas generationsystem includes a first solids separation device having: a firstseparation input in fluid communication with the first reactor productgas output; a first separation char output in fluid communication withthe second reactor char input; and, a first separation gas output. Inembodiments, the three-stage energy-integrated product gas generationsystem includes a second solids separation device having: a secondseparation input in fluid communication with the second reactor productgas output; a second separation solids output in fluid communicationwith a solids transfer conduit; and, a second separation gas output. Inembodiments, the three-stage energy-integrated product gas generationsystem includes a combined reactor product gas conduit in fluidcommunication with both the first separation gas output and the secondseparation gas output and configured to combine product gas created byboth the first reactor and the second reactor.

In embodiments, the first interior comprises: a first reactor dense bedzone; a first reactor feed zone located above the first reactor densebed zone; and, a first reactor splash zone located above the firstreactor feed zone. In embodiments, the first reactor dense bed zonereactant input is configured to receive a first reactor dense bed zonereactant into the first reactor dense bed zone; the first reactor feedzone reactant input is configured to receive a first reactor feed zonereactant into the first reactor feed zone; and the first reactor splashzone reactant input is configured to receive a first reactor splash zonereactant into the first reactor splash zone. In embodiments, thethree-stage energy-integrated product gas generation system includes atleast three first reactor feed zone reactant inputs; and, at least threefirst reactor splash zone reactant inputs.

In embodiments, the first reactor includes a first reactor dense bedzone oxygen-containing gas input configured to receive a first reactoroxygen-containing gas into the first reactor dense bed zone; a firstreactor feed zone oxygen-containing gas input configured to receive afirst reactor feed zone oxygen-containing gas into the first reactorfeed zone; and a first reactor splash zone oxygen-containing gas inputconfigured to receive a first reactor splash zone oxygen-containing gasinto the first reactor splash zone. In embodiments, the first rectorincludes at least three first reactor feed zone oxygen-containing gasinputs; and, at least three first reactor splash zone oxygen-containinggas inputs.

In embodiments, the second interior comprises: a second reactor densebed zone; a second reactor feed zone located above the second reactordense bed zone; and, a second reactor splash zone located above thesecond reactor feed zone.

In embodiments, the second reactor dense bed zone reactant inputconfigured to receive a second reactor dense bed zone reactant into thesecond reactor dense-bed zone; the second reactor feed zone reactantinput configured to receive a second reactor feed zone reactant into thesecond reactor feed zone; and, the second reactor splash zone reactantinput configured to receive a second reactor splash zone reactant intothe second reactor splash zone. In embodiments, the second reactorincludes at least three second reactor feed zone reactant inputs; and atleast three second reactor splash zone reactant inputs.

In embodiments, the second reactor includes a second reactor dense bedzone oxygen-containing gas input configured to receive a second reactoroxygen-containing gas into the second reactor dense bed zone; a secondreactor feed zone oxygen-containing gas input configured to receive asecond reactor feed zone oxygen-containing gas into the second reactorfeed zone; and a second reactor splash zone oxygen-containing gas inputconfigured to receive a second reactor splash zone oxygen-containing gasinto the second reactor splash zone. In embodiments, the three-stageenergy-integrated product gas generation system includes at least threesecond reactor feed zone oxygen-containing gas inputs; and, at leastthree second reactor splash zone oxygen-containing gas inputs.

In embodiments, a second reactor solids output; and a first reactorsolids input are in fluid communication and the first reactor solidsinput is configured to receive, into the first interior, second reactorparticulate heat transfer material present in the second interior.

In embodiments, the first reactor includes a first reactor first heatexchanger in thermal contact with the first interior, the first reactorfirst heat exchanger comprising: a first reactor first heat exchangerfuel inlet configured to receive a first reactor first heat exchangerfuel at a first inlet temperature; and a first reactor first heatexchanger combustion stream outlet configured to output a first reactorfirst heat exchanger combustion stream, at a first outlet temperature.

In embodiments, an auxiliary heat exchanger is external to the firstreactor and in thermal contact with the first reactor first heatexchanger combustion stream exiting the first reactor first heatexchanger combustion stream outlet; wherein the auxiliary heat exchangeris configured to transfer heat from the first reactor first heatexchanger combustion stream to an auxiliary heat exchanger heat transfermedium which exits the auxiliary heat exchanger via auxiliary heatexchanger heat transfer medium outlet conduit. In embodiments, theauxiliary heat exchanger heat transfer medium outlet conduit is in fluidcommunication with the second reactor heat transfer medium inlet, tothereby supply the auxiliary heat exchanger heat transfer medium to thesecond reactor heat exchanger. In embodiments, a portion of the thirdreactor heat transfer medium is transferred from the outlet of the thirdreactor heat exchanger to the inlet of the auxiliary heat exchanger foruse as the auxiliary heat exchanger heat transfer medium. Inembodiments, a steam turbine with an integrated generator is configuredto accept the superheated heat transfer medium discharged from theauxiliary heat exchanger to produce power.

In embodiments, the first reactor includes at least two first reactorheat exchangers positioned in the first interior and vertically spacedapart from one another along a height dimension of the first interior;wherein: alternate first reactor heat exchangers along said heightdimension are arranged cross-wise to one another such that, in a topview of the first interior, the four first reactor heat exchangersdefine four open vertically extending quadrants. In embodiments, thefirst reactor includes six first reactor carbonaceous material inputs tothe first interior; wherein: only two of the six first reactorcarbonaceous material inputs are configured to inject carbonaceousmaterial into the vertically extending quadrants.

In embodiments, the three-stage energy-integrated product gas generationsystem includes at least two first reactors in fluid communication onecommon third reactor, each first reactor configured to produce a sourceof first reactor product gas. In embodiments, the three-stageenergy-integrated product gas generation system includes at least twosecond reactors in fluid communication with one common third reactor;each second reactor configured to produce a source of second reactorproduct gas which is supplied to the common third reactor.

In embodiments, the third reactor further comprises an annulus-typeburner at a top portion thereof; the annulus-type burner has annularport configured to receive an oxygen-containing gas, and a central portconfigured to receive a hydrocarbon stream; and the annulus-type burnerfurther comprises a nozzle through which a combustion stream is outputinto a reaction zone of the third reactor (300).

In embodiments, the disclosure relates to a method for producing a H2,CO, and CO2 from a carbonaceous material using a first reactor, a secondreactor, and a third reactor, the method comprising:

-   (a) reacting carbonaceous material with a steam reactant in the    first reactor and producing a first reactor product gas containing    char;-   (b) introducing at least a portion of the char generated in step (a)    into the second reactor;-   (c) reacting the char of step (b) with an oxygen-containing gas in    the second reactor and producing a second reactor product gas;-   (d) transferring the first reactor product gas generated in step (a)    and the second reactor product gas generated in step (c) to the    third reactor, to form a combined product gas;-   (e) reacting the combined product gas with an oxygen-containing gas    in the third reactor to generate a third reactor product gas and    heat;-   (f) transferring heat generated in step (e) to a heat transfer    medium contained within a third reactor heat exchanger in thermal    contact with the interior of the third reactor;-   (g) transferring at least some of the heat transfer medium which has    passed through the third reactor heat exchanger, to a second reactor    heat exchanger in thermal contact with the interior of the second    reactor;-   (h) introducing a first portion of the heat transfer medium which    has passed through the second reactor heat exchanger, into the first    reactor as the steam reactant of step (a).

In embodiments, a second portion of the heat transfer medium which haspassed through the second reactor heat exchanger may be transferred intothe second reactor as a reactant. In embodiments, an oxygen-containinggas may be transferred to the first reactor, said oxygen-containing gasreacting with the carbonaceous material and the steam. In embodiments,char from the first reactor product gas is separated prior to beingtransferred to the second reactor prior to step (b). In embodiments, thefirst reactor product gas of step (a) further comprises H2, CO, CO2,semi-volatile organic compounds (SVOC) and volatile organic compounds(VOC).

In embodiments, the char in the first reactor product gas has a carboncontent of about 10% carbon to about 90% carbon on a weight basis. Inembodiments, the char in the first reactor product gas has an ashcontent range from about 90% ash to about 10% ash on a weight basis. Inembodiments, the second reactor product gas of step (c) furthercomprises solids. In embodiments, the solids contained within secondreactor product gas comprises about 0% to about 90% carbon on a weightbasis. In embodiments, the solids contained within second reactorproduct gas comprises about 5% to about 30% carbon on a weight basis. Inembodiments, the solids contained within second reactor product gascomprises about 10% to about 100% ash on a weight basis. In embodiments,the solids contained within second reactor product gas comprises about70% to about 95% ash on a weight basis. In embodiments, the carbonconversion rate in the first reactor is in the range from about 50% toabout 99%. In embodiments, the carbon conversion rate in the firstreactor is in the range from about 75% to about 95%. In embodiments, thesecond reactor converts into said second reactor product gas, 50% to 99%of the carbon contained within char transferred from the first reactorto the second reactor.

In embodiments, the first reactor product gas generated in step (a) andthe second reactor product gas generated in step (c) are combined, priorto being transferred into the third reactor. In embodiments, in step(e): the combined product gas includes SVOC, VOC and char from the firstreactor product gas, and said SVOC, VOC and char reacts with saidoxygen-containing gas to generate said third reactor product gas andheat. In embodiments, in step (e), the third reactor product gascomprises H2, CO, and CO2. In embodiments, in step (e), theoxygen-containing gas is superstoichiometric. In embodiments,superstoichiometric oxygen-containing gas is combusted with a firsthydrocarbon stream to produce a first portion of the CO2 in the thirdreactor product gas. In embodiments, first hydrocarbon stream is naturalgas. In embodiments, the superstoichiometric oxygen-containing gas iscombusted with a second hydrocarbon stream to produce a second portionof the CO2 in the third reactor product gas. In embodiments, the secondhydrocarbon stream comprises naphtha transferred from a downstreamUpgrading System. In embodiments, the superstoichiometricoxygen-containing gas is combusted with a third hydrocarbon stream toproduce a third portion of the CO2 in the third reactor product gas. Inembodiments, the third hydrocarbon stream is an off-gas transferred froma downstream Upgrading System.

In embodiments, a hydrocarbon stream and an oxygen-containing gas streamare combined and combusted together in an annulus type burner connectedto the third reactor and expelling a combustion stream into the thirdreactor, the combustion stream including uncombusted oxygen-containinggas; wherein all the oxygen-containing gas used in the reaction of step(e) with the combined product gas comprises uncombustedoxygen-containing gas from the combustion stream. In embodiments, theburner accepts a hydrocarbon stream and oxygen-containing gas streamthrough concentric ports, wherein the oxygen-containing gas is injectedinto an annular port, and the hydrocarbon stream is injected to thecentral port. In embodiments, a combustion stream exits the nozzle ofthe burner within the range of 200 feet per minute (ft/m) to the speedof sound. In embodiments, a combustion stream exits the nozzle of theburner within the range of about 50 feet per second (ft/s) to about 300feet per second (ft/s). In embodiments, the burner operates as aHelmholtz pulse combustion resonator and the combustion stream exits thenozzle of the burner at an average flow velocity greater than 300 ft/sand the sound intensity in the burner is within the range of about 110dB to about 190 dB. In embodiments, a portion of the combustion streamexits the burner to contact a portion of the combined product gas. Inembodiments, the combustion stream reacts with a the combined productgas at an average reaction time ranging from about 0.0001 seconds toabout 5.0 seconds. In embodiments, the heat transfer medium issuperheated when it is in the second reactor heat exchanger. Inembodiments, the superheated heat transfer medium is transferred intothe second reactor to help generate the second reactor product gas.

In embodiments, (i) the first reactor product gas (122) has a first H2to CO ratio; (ii) the second reactor product gas (222) has a second H2to CO ratio; (iii) the third reactor product gas (322) has a third H2 toCO ratio; (iv) the first H2 to CO ratio is greater than the second H2 toCO ratio; and (v) the second H2 to CO ratio is greater than the third H2to CO ratio. In embodiments, (i) the first reactor product gas (122) hasa first CO to CO2 ratio; (ii) the second reactor product gas (222) has asecond CO to CO2 ratio; (iii) the third reactor product gas (322) has athird CO to CO2 ratio; (iv) the third CO to CO2 ratio is greater thanthe second CO to CO2 ratio; and (v) the second CO to CO2 ratio isgreater than the first CO to CO2 ratio.

In embodiments, a fuel source is combusted in a first reactor heatexchanger to form a combustion stream, said combustion stream indirectlyheating particulate heat transfer material present in the first reactor.In embodiments, the heat transfer medium which has passed through thethird reactor heat exchanger is superheated with heat from thecombustion stream. In embodiments, the superheated heat transfer mediumis introduced to a steam turbine having an integrated generator toproduce power.

In embodiments, the first reactor operates at a first pressure; thesecond reactor operates at a second pressure which is lower than thefirst pressure; and, the third reactor operates at a third pressurewhich is lower than the second pressure.

In embodiments, a particulate heat transfer material is provided in thefirst reactor to promote the reaction between the carbonaceous materialand steam. In embodiments, the particulate heat transfer material istransferred from the second reactor to the first reactor.

In embodiments, the first reactor includes particulate heat transfermaterial comprised of Geldart Group A solids; and the Geldart Group Asolids comprise one or more from the group consisting of inert material,catalyst, sorbent, and engineered particles. In embodiments, theengineered particles comprise one or more from the group consisting ofalumina, zirconia, sand, olivine sand, limestone, dolomite, catalyticmaterials, microballoons, and microspheres.

In embodiments, the second reactor includes particulate heat transfermaterial (105) is comprised of Geldart Group B solids; the Geldart GroupB solids comprise one or more from the group consisting of inertmaterial, catalyst, sorbent, and engineered particles. In embodiments,the engineered particles comprise one or more from the group consistingof alumina, zirconia, sand, olivine sand, limestone, dolomite, catalyticmaterials, microballoons, microspheres, and combinations thereof.

In embodiments, the first reactor includes particulate heat transfermaterial (105) is comprised of both Geldart Group A and B solids; andthe Geldart Group A and B solids together comprise one or more from thegroup consisting of inert material, catalyst, sorbent, and engineeredparticles. In embodiments, the engineered particles comprise one or morefrom the group consisting of alumina, zirconia, sand, olivine sand,limestone, dolomite, catalytic materials, microballoons, andmicrospheres.

In embodiments, the first reactor at a temperature between 320° C. and569.99° C. to endothermically react the carbonaceous material in thepresence of steam to produce the first reactor product gas. Inembodiments, the first reactor at a temperature between 570° C. and 900°C. to endothermically react the carbonaceous material in the presence ofsteam to produce the first reactor product gas. In embodiments, thesecond reactor at a temperature between 500° C. and 1,400° C. toexothermically react the char in the presence of an oxygen-containinggas to produce the second reactor product gas. In embodiments, the thirdreactor at a temperature between 1,100° C. and 1,600° C. toexothermically react a portion of the first reactor product gas in thepresence of an oxygen-containing gas to produce the third reactorproduct gas.

In embodiments, the disclosure is related to a method for convertingcarbonaceous material into at least one liquid fuel, the methodcomprising:

-   (i) combining the carbonaceous material and carbon dioxide in a    feedstock delivery system;-   (ii) producing a third reactor product gas in accordance with the    method of claim 28;-   (iii) compressing at least a portion of the third reactor product    gas to thereby form a compressed product gas;-   (iv) removing carbon dioxide from the compressed product gas, and    supplying a first portion of the removed carbon dioxide to the    feedstock delivery system for combining with the carbonaceous    material in step (i);-   (v) reacting the compressed product gas with a catalyst after    removing carbon dioxide; and-   (vi) synthesizing at least one liquid fuel from the compressed    product gas, after reacting the compressed product gas with a    catalyst.

In embodiments, the liquid fuel comprises Fischer-Tropsch Products whichmay be upgraded into chemical compounds selected from the groupconsisting of diesel, jet fuel, and naphtha and combinations thereof. Inembodiments, a portion of the naphtha is transferred to the thirdreactor.

In embodiments, the first reactor has a steam to carbonaceous materialweight ratio in the range of about 0.125:1 to about 3:1. In embodiments,the first reactor has a carbon dioxide to carbonaceous material weightratio in the range of about 0:1 to about 1:1. In embodiments, the firstreactor has an oxygen-containing gas to carbonaceous material weightratio in the range of about 0:1 to about 0.5:1. In embodiments, thesecond reactor has a steam to char-carbon weight ratio in the range ofabout 0:1 to about 2.5:1. In embodiments, the second reactor has anoxygen-containing gas to char-carbon weight ratio in the range of about0:1 to about 2:1. In embodiments, the second reactor has a carbondioxide to char-carbon weight ratio in the range of about 0:1 to about2.5:1. In embodiments, the first reactor and second reactor operate at asuperficial fluidization velocity range between 0.5 ft/s to about 25.0ft/s. In embodiments, the first reactor operates at a superficialfluidization velocity range between 0.6 ft/s to about 1.2 ft/s. Inembodiments, the first reactor operates at a superficial fluidizationvelocity range between 0.8 ft/s to about 1 ft/s. In embodiments, thesecond reactor operates at a superficial fluidization velocity rangebetween 0.2 ft/s to about 0.8 ft/s. In embodiments, the second reactoroperates at a superficial fluidization velocity range between 0.3 ft/sto about 0.5 ft/s.

In embodiments, at least two first reactors are in fluid communicationwith one common third reactor, each first reactor producing firstreactor product gas. In embodiments, the first reactor is fed about 500tons carbonaceous material, per day. In embodiments, at least two secondreactors are in fluid communication with one common third reactor, eachsecond reactor producing second reactor product gas. In embodiments, atleast one of the second reactors is equipped with a particulateclassification chamber; and configured to remove agglomerates or inertfeedstock contaminants via the particulate classification chamber.

This disclosure further relates to the generation of product gas fromcarbonaceous materials using a continuous, uninterrupted, and reliablefluidized bed thermochemical reactor and particulate classificationsystem. More specifically, the present disclosure further relates to acontinuously operating product gas generation system integrated with aparticulate classification vessel for cleaning bed material byseparating via size and density classification smaller group Geldartsolids for recycle back to the first reactor and allowing for theremoval of comparatively larger Geldart solids from the system via aclassifier vessel. The content of the disclosure is particularlyapplicable to the production of product gas from municipal solid waste(MSW) or refuse derived fuel (RDF) due to the improved cooperationbetween the first reactor and classifier to accommodate continuous,uninterrupted, and reliable product gas generation notwithstanding theunpredictable variations in carbonaceous material feedstockcharacterization. This disclosure further relates to systems and methodsto mediate the unavoidable introduction of inert contaminants containedwithin carbonaceous material that would otherwise tend to accumulatewithin the fluidized bed resulting in defluidization and unplannedshut-down and maintenance. In embodiments, a fluidized bed having a meanbed particle characteristic including Geldart Group B solids may accepta solid MSW carbonaceous material having inert feedstock contaminants ofGeldart Group D that are incapable of being thermochemically convertedinto product gas and instead unavoidably accumulate at unpredictablelevels within the dense fluid bed causing defluidization and ultimatelyrequiring process termination or shut-down.

In embodiments, the disclosure relates to a method for convertingmunicipal solid waste (MSW) into at least one liquid fuel, the MSWcontaining Geldart Group D inert feedstock contaminants, the methodcomprising:

-   (a) combining the MSW and carbon dioxide in a feedstock delivery    system;-   (b) introducing, into a first interior of a first reactor containing    bed material, steam and the combined MSW and carbon dioxide from the    feedstock delivery system;-   (c) reacting, in the first reactor, the MSW with steam and carbon    dioxide, in an endothermic thermochemical reaction to generate a    first reactor product gas containing char and leaving unreacted    Geldart Group D inert feedstock contaminants in the bed material;-   (d) cleaning the bed material with carbon dioxide to remove said    unreacted Geldart Group D inert feedstock contaminants;-   (e) introducing, into a second reactor containing a second    particulate heat transfer material, an oxygen-containing gas and a    portion of the char;-   (f) reacting, in the second reactor, the char with the    oxygen-containing gas, in an exothermic thermochemical reaction to    generate a second reactor product gas;-   (g) introducing, into a third reactor, an oxygen-containing gas and    the first reactor product gas generated in step (c) and the second    reactor product gas generated in step (f);-   (h) reacting, in the third reactor; the product gas with the    oxygen-containing gas, in an exothermic thermochemical reaction to    generate a third reactor product gas;-   (i) compressing the first and/or second reactor product gas to    thereby form a compressed product gas;-   (j) removing carbon dioxide from the compressed product gas, and    supplying a first portion of the removed carbon dioxide to the    feedstock delivery system for combining with the MSW in step (a);    and supplying a second portion of the removed carbon dioxide to    clean the bed material in step (d);-   (k) reacting the compressed product gas with a catalyst after    removing carbon dioxide; and-   (l) synthesizing at least one liquid fuel from the compressed    product gas, after reacting the compressed product gas with a    catalyst;

wherein:

the Geldart Group D inert feedstock contaminants comprise whole unitsand/or fragments of one or more from the group consisting of allenwrenches, ball bearings, batteries, bolts, bottle caps, broaches,bushings, buttons, cable, cement, chains, clips, coins, computer harddrive shreds, door hinges, door knobs, drill bits, drill bushings,drywall anchors, electrical components, electrical plugs, eye bolts,fabric snaps, fasteners, fish hooks, flash drives, fuses, gears, glass,gravel, grommets, hose clamps, hose fittings, jewelry, key chains, keystock, lathe blades, light bulb bases, magnets, metal audio-visualcomponents, metal brackets, metal shards, metal surgical supplies,mirror shreds, nails, needles, nuts, pins, pipe fittings, pushpins,razor blades, reamers, retaining rings, rivets, rocks, rods, routerbits, saw blades, screws, sockets, springs, sprockets, staples, studs,syringes, USB connectors, washers, wire, wire connectors, and zippers.

In embodiments, the disclosure is related to a municipal solid waste(MSW) energy recovery system for converting MSW containing inertfeedstock contaminants, into a product gas, the system comprising:

(a) a first reactor comprising: a first reactor interior suitable foraccommodating a bed material and endothermically reacting MSW in thepresence of steam to produce product gas; a first reactor carbonaceousmaterial input for introducing MSW into the first reactor interior; afirst reactor reactant input for introducing steam into the firstinterior; a first reactor product gas output through which product gasis removed; a classified recycled bed material input in fluidcommunication with an upper portion of the first reactor interior; aparticulate output connected to a lower portion of the first reactorinterior, and through which a mixture of bed material and unreactedinert feedstock contaminants selectively exits the first reactorinterior; and,

(b) at least one particulate classification vessel in fluidcommunication with the first reactor interior, the vessel comprising:(i) a mixture input connected to the particulate output, for receivingsaid mixture from the first reactor interior; (ii) a classifier gasinput connected to a source of classifier gas, for receiving classifiergas to promote separation of said bed material from said unreacted inertfeedstock contaminants within said vessel; (iii) a bed material outputconnected to the classified recycled bed material input of the firstreactor interior via a classifier riser conduit, for returning bedmaterial separated from said mixture to the first reactor interior; and(iv) a contaminant output for removing unreacted inert feedstockcontaminants which have been separated from said mixture, within thevessel;

wherein: a mixture transfer valve is positioned between the particulateoutput and the mixture input, to selectively control transfer of saidmixture from the first reactor to the vessel; a gas distributor valve ispositioned to separate the classifier interior into a classifier zoneand a gas distribution zone; a classification gas transfer valve ispositioned between the source of classifier gas and the classifier gasinput, to selectively provide said classifier gas to the vessel; a bedmaterial riser recycle transfer valve is positioned between the bedmaterial output and the classified recycled bed material input, toselectively return bed material separated from said mixture, to thefirst reactor interior; and an inert feedstock contaminant drain valveconfigured to selectively remove unreacted inert feedstock contaminantswhich have been separated from said mixture.

In embodiments, the gas distributor valve has perforations so as topermit the valve to be in the closed position and still allow (a)classifier gas to pass up through the valve, and (b) inert feedstockcontaminants and bed material to not pass down through the valve. Inembodiments, the perforations of the gas distributor valve range fromabout 10 to about 100 microns. In embodiments, the classifier vesselfurther comprises a classifier depressurization gas output; and adepressurization vent valve connected to the classifier depressurizationgas output to selectively vent the vessel. In embodiments, theclassifier gas is carbon dioxide. In embodiments, the product gascomprises carbon dioxide; and a first portion of the carbon dioxide inthe product gas is introduced into the vessel as the classifier gas.

In embodiments, a master controller configured to operate the system inany one of a plurality of states, including: a first state in which themixture transfer valve, gas distributor valve, classification gastransfer valve, bed material riser recycle transfer valve, and inertfeedstock contaminant drain valve are closed; a second state in whichthe mixture transfer valve is open and the remainder of said valves areclosed, to allow said mixture to enter the vessel; a third state inwhich the classification gas transfer valve and the bed material riserrecycle transfer valve are open and the remainder of said valves areclosed, to promote separation of said bed material from said mixture andrecycling of separated bed material back into the first reactor; afourth state in which the depressurization vent valve is open and theremainder of said valves are closed, to allow the vessel to vent; and afifth state in which the gas distributor valve and inert feedstockcontaminant drain valve are open and the remainder of said valves areclosed, to remove unreacted inert feedstock contaminants from thevessel.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made in detail to various embodiments of thedisclosure. Each embodiment is provided by way of explanation of thedisclosure, not limitation of the disclosure. It will be apparent tothose skilled in the art that modifications and variations can be madein the disclosure without departing from the teaching and scope thereof,for instance, features illustrated or described as part of oneembodiment to yield a still further embodiment derived from the teachingof the disclosure. Thus, it is intended that the disclosure or contentof the claims cover such derivative modifications and variations to comewithin the scope of the disclosure or claimed embodiments describedherein and their equivalents.

Additional objects and advantages of the disclosure will be set forth inpart in the description which follows, and in part will be obvious fromthe description, or may be learned by practice of the claims. Theobjects and advantages of the disclosure will be attained by means ofthe instrumentalities and combinations and variations particularlypointed out in the appended claims.

The accompanying figures show schematic process flowcharts of preferredembodiments and variations thereof. A full and enabling disclosure ofthe content of the accompanying claims, including the best mode thereofto one of ordinary skill in the art, is set forth more particularly inthe remainder of the specification, including reference to theaccompanying figures showing how the preferred embodiments and othernon-limiting variations of other embodiments described herein may becarried out in practice, in which:

FIG. 1 shows a simplistic block flow control volume diagram of oneembodiment of an three-stage energy integrated product gas generationsystem (1001) used as a Product Gas Generation System (3000).

FIG. 2 shows an embodiment of a three-stage energy integrated productgas generation method.

FIG. 3 shows a simplistic block flow control volume diagram of oneembodiment of an three-stage energy integrated product gas generationsystem (1001) used as a Product Gas Generation System (3000);

FIG. 4 elaborates upon the non-limiting embodiment of FIG. 3 howevershows the third reactor (300) having both a first reactor product gasinput (303) and a second reactor product gas input (305) as opposed toonly one combined product gas input (304).

FIG. 5 elaborates upon the non-limiting embodiment of FIG. 3 furtherincluding an auxiliary heat exchanger (HX-2) configured to transfer heatfrom a combustion stream (114) to an auxiliary heat exchanger heattransfer medium (164) that is fluid communication with the heat transfermedium inlet (212) of the second reactor heat exchanger (HX-B) via aheat transfer medium outlet conduit (170).

FIG. 6 elaborates upon the non-limiting embodiment of FIG. 5 where aportion of the third reactor heat transfer medium (310) is transferredfrom the outlet (316) of the third reactor heat exchanger (HX-C) to theinlet (166) of the auxiliary heat exchanger (HX-2) for use as theauxiliary heat exchanger heat transfer medium (164).

FIG. 7 is a detailed view of FIG. 3 showing a non-limiting embodiment ofa First Stage Product Gas Generation Control Volume (CV-3A) and FirstStage Product Gas Generation System (3A) of a three-stageenergy-integrated product gas generation system (1001) including a firstreactor (100) equipped with a dense bed zone (AZ-A), feed zone (AZ-B),and splash zone (AZ-C), along with the first reactor carbonaceousmaterial input (104), valves, sensors, and controllers.

FIG. 8 elaborates upon the non-limiting embodiment of FIG. 7 furtherincluding multiple carbonaceous material inputs (104A, 104B, 104C, 104D)and multiple feed zone steam/oxygen inputs (AZB2, AZB3, AZB4, AZB5)positioned in the feed zone (AZ-B) along with multiple splash zonesteam/oxygen inputs (AZC2, AZC3, AZC4, AZC5) positioned in the splashzone (AZ-C).

FIG. 9 shows a non-limiting embodiment of a first reactor feed zonecircular cross-sectional view (XAZ-B) from the embodiment of FIG. 8.

FIG. 10 shows a non-limiting embodiment of a first reactor feed zonerectangular cross-sectional view (XAZ-B) from the embodiment of FIG. 8.

FIG. 11 shows a non-limiting embodiment of a first reactor feed zonecross-sectional view (XAZ-B) from the embodiment of FIG. 8 where onlytwo of the six first reactor (100) carbonaceous material inputs(104B,104E) are configured to inject carbonaceous material intovertically extending quadrants (Q1, Q2, Q3, Q4).

FIG. 12 shows a non-limiting embodiment of a first reactor splash zonecross-sectional view (XAZ-C) from the embodiment of FIG. 8.

FIG. 13 is a detailed view of FIG. 3 showing a non-limiting embodimentof a Second Stage Product Gas Generation Control Volume (CV-3B) andSecond Stage Product Gas Generation System (3B) of a three-stageenergy-integrated product gas generation system (1001) including asecond reactor (200) equipped with a dense bed zone (BZ-A), feed zone(BZ-B), and splash zone (BZ-C), along with a second reactor heatexchanger (HX-B), first solids separation device (150), second solidsseparation device (250), solids flow regulator (245), riser (236),dipleg (244), and valves, sensors, and controllers.

FIG. 14 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 13, including:one first solids separation device (150); four second reactor first charinputs (204A, 204B, 204C, 204D); four feed zone steam/oxygen inputs(BZB2, BZB3, BZB4, BZB5); and, where the combined reactor product gasconduit (230) is configured to blend the first reactor product gas (126)with the second reactor product gas (226).

FIG. 15 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 13 where thefirst reactor product gas (126) is not combined with the second reactorproduct gas (226).

FIG. 16 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 13, including:two first solids separation devices (150A1, 150A2); two solids flowregulators (245A, 245B); four second reactor first char inputs (204A,204B, 204C, 204D); four feed zone steam/oxygen inputs (BZB2, BZB3, BZB4,BZB5); and, where the combined reactor product gas conduit (230) isconfigured to blend the first reactor product gas (126A1, 126A2) withthe second reactor product gas (226).

FIG. 17 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 16 where thefirst reactor product gas (126A1, 126A2) is not combined with the secondreactor product gas (226).

FIG. 18 shows a non-limiting embodiment of a second reactor splash zonecross-sectional view (XBZ-C) of the embodiment in FIG. 13, includingfour splash zone steam/oxygen inputs (BZC2, BZC3, BZC4, BZC5) configuredto accept a source of splash zone steam/oxygen (BZC1).

FIG. 19 elaborates upon the non-limiting embodiment of FIG. 7 furtherincluding two particulate classification vessels (A1A, A1B) that areconfigured to accept a bed material, inert feedstock contaminant mixture(A4A, A4AA), and a classifier gas (A16, A16A) and to clean and recyclethe bed material portion back to the first interior (101) of the firstreactor (100) while removing the inert feedstock contaminant portionfrom the system as a solids output (3A-OUT3).

FIG. 20 depicts the Classification Valve States for Automated ControllerOperation of a typical particulate classification procedure. FIG. 20 isto be used in conjunction with FIG. 19 and depicts a listing of valvestates that may be used in a variety of methods to operate valvesassociated with the particulate classification vessels (A1A, A1B).

FIG. 21 elaborates upon the non-limiting embodiment of FIG. 7 and FIG.19 including another embodiment of a particulate classification vessel(A1A) including gas distributor valve (V91) that separates theclassifier interior (INA) into a classifier zone (INA1) and a gasdistribution zone (INA2) and where the classifier (A1A) is configured toaccept a bed material, inert feedstock contaminant mixture (A4A), and aclassifier gas (A16) and to clean and recycle the bed material portionback to the first interior (101) of the first reactor (100) whileremoving the inert feedstock contaminant portion from the system as asolids output (3A-OUT3).

FIG. 21A shows a non-limiting embodiment of a classifier gas distributorvalve cross-sectional view (X500) of the embodiment in FIG. 21,including depicting a top-down view of one embodiment of a gasdistributor valve (V91) in the closed position.

FIG. 21B shows a non-limiting embodiment of a classifier gas distributorvalve cross-sectional view (X500) of the embodiment in FIG. 21,including depicting a top-down view of one embodiment of a gasdistributor valve (V91) in the open position.

FIG. 22 depicts the Classification Valve States as described in FIG. 20further including the operation of a gas distributor valve (V91). FIG.22 is to be used in conjunction with FIG. 21 and depicts a listing ofvalve states that may be used in a variety of methods to operate valvesassociated with one embodiment of a particulate classification vessel(A1A).

FIG. 23 shows a detailed view of one non-limiting embodiment of a ThirdStage Product Gas Generation Control Volume (CV-3C) and Third StageProduct Gas Generation System (3C) of a three-stage energy-integratedproduct gas generation system (1001) in accordance with FIG. 3 alsoshowing a third reactor (300) equipped with a third interior (301), andalso showing a combustion zone (CZ-A), reaction zone (CZ-B), coolingzone (CZ-C), quench zone (CZ-E), steam drum (350), and valves, sensors,and controllers.

FIG. 24 depicts one non-limiting embodiment of a three-stageenergy-integrated product gas generation system (1001) comprised of fourfirst reactors (100A, 100B, 100C, 100D), and four second reactors (200A,200B, 200C, 200D), each with their own separate first solids separationdevice (150A, 150B, 150C, 150D), and second solids separation device(250A, 250B, 250C, 250D), and combined reactor product gas conduits(230A, 230B, 230C, 230D) for feeding into one common third reactor(300).

FIG. 25 shows Product Gas Generation System (3000) of FIG. 1 utilized inthe framework of an entire Refinery Superstructure System (RSS). Inembodiments, the RSS system as shown in FIG. 25 may be configured toemploy the use of the three-stage energy integrated product gasgeneration method as elaborated upon in FIG. 1.

FIG. 26 shows Product Gas Generation System (3000) of FIG. 1 utilized inan entire Refinery Superstructure (RSS) system further including aPrimary Gas Clean-Up Heat Exchanger (HX-4) in fluid communication withthe second reactor heat transfer medium inlet (212) and configured toremove heat from at least a portion of the product gas input (4-IN1).

FIG. 27 further depicts a first reactor (100), first solids separationdevice (150), dipleg (244), solids flow regulator (245), second reactor(200), particulate classification chamber (B1), second solids separationdevice (250), second reactor heat exchanger (HX-B), third reactor (300),third reactor heat exchanger (HX-C), steam drum (350), Primary Gas CleanUp Heat Exchanger (HX-4), venturi scrubber (380), scrubber (384),decanter separator (388), solids separator (398), and a scrubberrecirculation heat exchanger (399).

DETAILED DESCRIPTION Notation and Nomenclature

Before the disclosed systems and processes are described, it is to beunderstood that the aspects described herein are not limited to specificembodiments, apparatus, or configurations, and as such can, of course,vary. It is also to be understood that the terminology used herein isfor the purpose of describing particular aspects only and, unlessspecifically defined herein, is not intended to be limiting.

The idea of a control volume is an extremely general concept used widelyin the study and practice of chemical engineering. Control volumes maybe used in applications that analyze physical systems by utilization ofthe laws of conservation of mass and energy. They may be employed duringthe analysis of input and output data of an arbitrary space, or region,usually being a chemical process, or a portion of a chemical process.They may be used to define process streams entering a single piece ofchemical equipment that performs a certain task, or they may be used todefine process streams entering a collection of equipment, and assetswhich work together to perform a certain task.

With respect to the surrounding text, a control volume is meaningful interms of defining the boundaries of a particular product gas generationsequence step or a sequence step related to the overarching topographyof an entire refinery superstructure. The arrangements of equipmentcontained within each control volume are the preferred ways ofaccomplishing each sequence step. Furthermore, all preferred embodimentsare non-limiting in that any number of combinations of unit operations,equipment and assets, including pumping, piping, and instrumentation,may be used as an alternate. However, it has been our realization thatthe preferred embodiments that make up each sequence step are thosewhich work best to generate a product gas from a carbonaceous materialusing two separate and successive upstream and downstream thermochemicalreactors that cooperate to efficiently and substantially completelyconvert a carbonaceous material into product gas while sharing heat fromsuccessive endothermic and exothermic reactions. Nonetheless, any typesof unit operations or processes may be used within any control volumeshown as long as it accomplishes the goal of that particular sequencestep.

As used herein the term “carbonaceous material” refers to a solid orliquid substance that contains carbon such as for instance, agriculturalresidues, agro-industrial residues, animal waste, biomass, cardboard,coal, coke, energy crops, farm slurries, fishery waste, food waste,fruit processing waste, lignite, municipal solid waste (MSW), paper,paper mill residues, paper mill sludge, paper mill spent liquors,plastics, refuse derived fuel (RDF), sewage sludge, tires, urban waste,wood products, wood wastes and a variety of others. All carbonaceousmaterials contain both “fixed carbon feedstock components” and “volatilefeedstock components”, such as for example woody biomass, MSW, or RDF.

As used herein the term “fixed carbon feedstock components” refers tofeedstock components present in a carbonaceous material other thanvolatile feedstock components, contaminants, ash or moisture. Fixedcarbon feedstock components are usually solid combustible residueremaining after the removal of moisture and volatile feedstockcomponents from a carbonaceous material.

As used herein the term “char” refers to a carbon-containing solidresidue derived from a carbonaceous material and is comprised of the“fixed carbon feedstock components” of a carbonaceous material. Charalso includes ash.

As used herein the term “char-carbon” refers to the mass fraction ofcarbon that is contained within the char transferred from the firstreactor to the second reactor.

As used herein the term “char-ash” refers to the mass fraction of ashthat is contained within the char transferred from the first reactor tothe second reactor.

As used herein the term “volatile feedstock components” refers tocomponents within a carbonaceous material other than fixed carbonfeedstock components, contaminants, ash or moisture.

As used herein the term “inert feedstock contaminants” or “inertcontaminants” refers to Geldart Group D particles contained within a MSWand/or RDF carbonaceous material. Geldart Group D solids comprise wholeunits and/or fragments of one or more of the group consisting of allenwrenches, ball bearings, batteries, bolts, bottle caps, broaches,bushings, buttons, cable, cement, chains, clips, coins, computer harddrive shreds, door hinges, door knobs, drill bits, drill bushings,drywall anchors, electrical components, electrical plugs, eye bolts,fabric snaps, fasteners, fish hooks, flash drives, fuses, gears, glass,gravel, grommets, hose clamps, hose fittings, jewelry, key chains, keystock, lathe blades, light bulb bases, magnets, metal audio-visualcomponents, metal brackets, metal shards, metal surgical supplies,mirror shreds, nails, needles, nuts, pins, pipe fittings, pushpins,razor blades, reamers, retaining rings, rivets, rocks, rods, routerbits, saw blades, screws, sockets, springs, sprockets, staples, studs,syringes, USB connectors, washers, wire, wire connectors, and zippers.

Generally speaking, Geldart grouping is a function of bed materialparticle size and density and the pressure at which the fluidized bedoperates. In the present context which is related to systems and/ormethods for converting municipal solid waste (MSW) into a product gasusing a fluidized bed, Geldart C Group solids range in size from betweenabout 0 and 29.99 microns, Geldart A Group solids range in size frombetween about 30 microns to 99.99 microns, Geldart B Group solids rangein size from between about 100 and 999.99 microns, and, Geldart D Groupsolids range in size greater than about 1,000 microns.

As used herein the term “product gas” refers to volatile reactionproducts, syngas, or flue gas discharged from a thermochemical reactorundergoing thermochemical processes including hydrous devolatilization,pyrolysis, steam reforming, partial oxidation, dry reforming, orcombustion.

As used herein the term “syngas” refers to a mixture of carbon monoxide(CO), hydrogen (H2), and other vapors/gases, also including char, if anyand usually produced when a carbonaceous material reacts with steam(H2O), carbon dioxide (CO2) and/or oxygen (02). While steam is thereactant in steam reforming, CO2 is the reactant in dry reforming.Generally, for operation at a specified temperature, the kinetics ofsteam reforming is faster than that of dry reforming and so steamreforming tends to be favored and more prevalent. Syngas might alsoinclude volatile organic compounds (VOC) and/or semi-volatile organiccompounds (VOC).

As used herein the term “volatile organic compounds” or acronym “(VOC)”or “VOC” refer to aromatics including benzene, toluene, phenol, styrene,xylene, and cresol. It also refers to low molecular weight hydrocarbonslike methane, ethane, ethylene, propane, propylene, etc.

As used herein the term “semi-volatile organic compounds” or acronym“(SVOC)” or “SVOC” refer to polyaromatics, such as indene, indane,naphthalene, methylnaphthalene, acenaphthylene, acenaphthalene,anthracene, phenanthrene, (methyl-) anthracenes/phenanthrenes,pyrene/fluoranthene, methylpyrenes/benzofluorenes, chrysene,benz[a]anthracene, methylchrysenes, methylbenz[a]anthracenes, perylene,benzo[a]pyrene, dibenz[a,kl]anthracene, and dibenz[a,h]anthracene.

As used herein the term “volatile reaction products” refers to vapor orgaseous organic species that were once present in a solid or liquidstate as volatile feedstock components of a carbonaceous materialwherein their conversion or vaporization to the vapor or gaseous statewas promoted by the processes of either hydrous devolatilization and/orpyrolysis. Volatile reaction products may contain both, non-condensablespecies, and condensable species which are desirable for collection andrefinement.

As used herein the term “oxygen-containing gas” refers to air,oxygen-enriched-air i.e. greater than 21 mole % oxygen, andsubstantially pure oxygen, i.e. greater than about 95 mole % oxygen (theremainder usually comprising nitrogen and rare gases).

As used herein the term “flue gas” refers to a vapor or gaseous mixturecontaining varying amounts of nitrogen (N2), carbon dioxide (CO2), water(H2O), and oxygen (O2). Flue gas is generated from the thermochemicalprocess of combustion.

As used herein the term “thermochemical process” refers to a broadclassification including various processes that can convert acarbonaceous material into product gas. Among the numerousthermochemical processes or systems that can be considered for theconversion of a carbonaceous material, the present disclosurecontemplates: hydrous devolatilization, pyrolysis, steam reforming,partial oxidation, dry reforming, and/or combustion. Thermochemicalprocesses may be either endothermic or exothermic in nature dependingupon the specific set of processing conditions employed. Stoichiometryand composition of the reactants, type of reactants, reactor temperatureand pressure, heating rate of the carbonaceous material, residence time,carbonaceous material properties, and catalyst or bed additives alldictate what sub classification of thermochemical processing the systemexhibits.

As used herein the term “thermochemical reactor” refers to a reactorthat accepts a carbonaceous material or char and converts it into one ormore product gases.

Hydrous Devolatilization Reaction:

As used herein the term “hydrous devolatilization” refers to anendothermic thermochemical process wherein volatile feedstock componentsof a carbonaceous material are converted primarily into volatilereaction products in a steam environment. Typically this subclassification of a thermochemical process involves the use of steam asa reactant and involves temperatures ranging from 320° C. and 569.99° C.(608° F. and 1,057.98° F.), depending upon the carbonaceous materialchemistry. Hydrous devolatilization permits release and thermochemicalreaction of volatile feedstock components leaving the fixed carbonfeedstock components mostly unreacted as dictated by kinetics.

Carbonaceous material+steam+heat→Volatile Reaction Products+Fixed CarbonFeedstock Components+steam

Pyrolysis Reaction:

As used herein the term “pyrolysis” or “devolatilization” is theendothermic thermal degradation reaction that organic material goesthrough in its conversion into a more reactive liquid/vapor/gas state.

Carbonaceous material+heat→VOC+SVOC+H2O+CO+CO2+H2+CH4+Other OrganicGases (CxHyOz)+Fixed Carbon Feedstock Components

Steam Reforming Reaction:

As used herein the term “steam reforming” refers to a thermochemicalprocess where steam reacts with a carbonaceous material to yield syngas.The main reaction is endothermic (consumes heat) wherein the operatingtemperature range is between 570° C. and 900° C. (1,058° F. and 1,652°F.), depending upon the feedstock chemistry.

H2O+C+Heat→H2+CO

Water Gas Shift Reaction:

As used herein the term “water-gas shift” refers to a thermochemicalprocess comprising a specific chemical reaction that occurssimultaneously with the steam reforming reaction to yield hydrogen andcarbon dioxide. The main reaction is exothermic (releases heat) whereinthe operating temperature range is between 570° C. and 900° C. (1,058°F. and 1,652° F.), depending upon the feedstock chemistry.

H2O+CO→H2+CO2+Heat

Dry Reforming Reaction:

As used herein the term “dry reforming” refers to a thermochemicalprocess comprising a specific chemical reaction where carbon dioxide isused to convert a carbonaceous material into carbon monoxide. Thereaction is endothermic (consumes heat) wherein the operatingtemperature range is between 600° C. and 1,000° C. (1,112° F. and 1,832°F.), depending upon the feedstock chemistry.

CO2+C+Heat→2CO

Partial Oxidation Reactions:

As used herein the term “partial oxidation” refers to a thermochemicalprocess wherein substoichiometric oxidation of a carbonaceous materialtakes place to exothermically produce carbon monoxide, carbon dioxideand/or water vapor. The reactions are exothermic (release heat) whereinthe operating temperature range is between 500° C. and 1,400° C. (932°F. and 2,552° F.), depending upon the feedstock chemistry. Oxygen reactsexothermically (releases heat): 1) with the carbonaceous material toproduce carbon monoxide and carbon dioxide; 2) with hydrogen to producewater vapor; and 3) with carbon monoxide to produce carbon dioxide.

4C+3O2→CO+CO2+Heat

C+½O2→CO+Heat

H2+½O2→H2O+Heat

CO+½O2→CO2+Heat

Combustion Reaction:

As used herein the term “combustion” refers to an exothermic (releasesheat) thermochemical process wherein at least the stoichiometricoxidation of a carbonaceous material takes place to generate flue gas.

C+O2→CO2+Heat

CH4+O2→CO2+2H2O+Heat

Some of these reactions are fast and tend to approach chemicalequilibrium while others are slow and remain far from reachingequilibrium. The composition of the product gas will depend upon bothquantitative and qualitative factors. Some are unit specific i.e.fluidized bed size/scale specific and others are feedstock specific. Thequantitative parameters are: feedstock properties, feedstock injectionflux, reactor operating temperature, pressure, gas and solids residencetimes, feedstock heating rate, fluidization medium and fluidizationflux; the qualitative factors are: degree of bed mixing and gas/solidcontact, and uniformity of fluidization and feedstock injection.

FIG. 1:

FIG. 1 shows a simplistic block flow control volume diagram of oneembodiment of an three-stage energy integrated product gas generationsystem (1001) used as a Product Gas Generation System (3000). TheProduct Gas Generation Control Volume (CV-3000) of FIG. 1 is comprisedof Product Gas Generation System (3000) that accepts a carbonaceousmaterial input (3-IN1) and generates a product gas output (3-OUT1)therefrom through at least one thermochemical process. The Product GasGeneration System (3000) contained within the Product Gas GenerationControl Volume (CV-3000) accepts a carbonaceous material (500) through acarbonaceous material input (3-IN1) and generates a product gas output(3-OUT1) therefrom through at least one thermochemical process.

The non-limiting embodiment of FIG. 1 depicts the Product Gas GenerationControl Volume (CV-3000) comprised of a First Stage Product GasGeneration Control Volume (CV-3A), a Second Stage Product Gas GenerationControl Volume (CV-3B), and a Third Stage Product Gas Generation ControlVolume (CV-3C) thermally integrated with one another and configured forthe conversion of carbonaceous materials into product gas.Correspondingly, the Product Gas Generation System (3000) of FIG. 1includes a First Stage Product Gas Generation System (3A), a SecondStage Product Gas Generation System (3B), and a Third Stage Product GasGeneration System (3C) thermally integrated with one another andconfigured for the conversion of carbonaceous materials into productgas.

In embodiments, three separate control volumes (CV-3A, CV-3B, CV-3C) areincluded within the Product Gas Generation Control Volume (CV-3000) tothermochemically convert the carbonaceous material input (3-IN1) into aproduct gas output (3-OUT1).

The First Stage Product Gas Generation System (3A) contained within theFirst Stage Product Gas Generation Control Volume (CV-3A) is configuredto accept a carbonaceous material input (3A-IN1) and generate a productgas output (3-OUT1) therefrom through at least one thermochemicalprocess.

The Second Stage Product Gas Generation System (3B) contained within theSecond Stage Product Gas Generation Control Volume (CV-3B) accepts thefirst reactor product gas output (3A-OUT1) as a first reactor productgas input (3B-IN1) and exothermically reacts a portion thereof withoxygen-containing gas input (3B-IN3) to generate heat and a product gasoutput (3B-OUT1).

The Third Stage Product Gas Generation System (3C) contained within theThird Stage Product Gas Generation Control Volume (CV-3C) accepts theproduct gas output (3B-OUT1) from the Second Stage Product GasGeneration System (3B) as a combined product gas input (3C-IN1) andexothermically reacts a portion thereof with an oxygen-containing gasinput (3C-IN3) to generate heat and a third reactor product gas output(3C-OUT1).

A third reactor heat exchanger (HX-C) is in thermal contact with theThird Stage Product Gas Generation System (3C) contained within theThird Stage Product Gas Generation Control Volume (CV-3C). The thirdreactor heat exchanger (HX-C) is in thermal contact with the exothermicreaction between the combined product gas input (3C-IN1) and theoxygen-containing gas input (3C-IN3). The third reactor heat exchanger(HX-C) is configured to accept a heat transfer medium, such as water orsteam, at a third reactor heat transfer medium inlet temperature (T0),from a third reactor heat transfer medium input (3C-IN2) and transferheat from the exothermic reaction taking place within the Third StageProduct Gas Generation System (3C) to the contents of the heat transfermedium input (3C-IN2) to result in a third reactor heat transfer mediumoutput (3C-OUT2). The third reactor heat transfer medium output(3C-OUT2) is in fluid communication with the second reactor heattransfer medium input (3B-IN2) of the second reactor heat exchanger(HX-B).

A second reactor heat exchanger (HX-B) is in thermal contact with theSecond Stage Product Gas Generation System (3B) contained within theSecond Stage Product Gas Generation Control Volume (CV-3B). The secondreactor heat exchanger (HX-B) is in thermal contact with an exothermicreaction between the first reactor product gas input (3B-IN1) andoxygen-containing gas input (3B-IN3). The second reactor heat exchanger(HX-B) is configured to accept a heat transfer medium, such as water orsteam, at a second reactor inlet temperature (T1), from a second reactorheat transfer medium input (3B-IN2) and transfer heat from theexothermic reaction taking place within the Second Stage Product GasGeneration System (3B) to the contents of the heat transfer medium input(3B-IN2). As a result, the second reactor heat transfer medium output(3B-OUT2) is at a second reactor outlet temperature (T2) that is higherthan the second reactor inlet temperature (T1). A portion of the secondreactor heat transfer medium output (3B-OUT2) is transferred to theFirst Stage Product Gas Generation Control Volume (CV-3A) at a firstreactor reactant temperature (TR1). In embodiments, the first reactorreactant temperature (TR1) is about equal to the second reactor outlettemperature (T2). In embodiments, the first reactor reactant temperature(TR1) is less than the second reactor outlet temperature (T2) due toheat losses in piping while transferring the heat transfer medium (210)from the outlet (216) of the second reactor heat exchanger (HX-B) to theFirst Stage Product Gas Generation System (3A).

The first reactor reactant input (3A-IN2) is in fluid communication withthe second reactor heat transfer medium output (3B-OUT2) and isconfigured to introduce at least a portion of the contents therein intothe First Stage Product Gas Generation System (3A) to react with thecarbonaceous material (500) to realize a first reactor product gasoutput (3A-OUT1).

The second reactor reactant input (208) is in fluid communication withthe second reactor heat transfer medium output (3B-OUT2) and isconfigured to introduce at least a portion of the contents therein intothe Second Stage Product Gas Generation System (3B) to react with aportion of the contents of the first reactor product gas input (3B-IN1)to realize a product gas output (3B-OUT1).

A first reactor heat exchanger (HX-A) is in thermal contact with theFirst Stage Product Gas Generation System (3A) to provide the energy toendothermically react the carbonaceous material (500) with the firstreactor reactant input (3A-IN2) to realize a first reactor product gasoutput (3A-OUT1). The first reactor heat exchanger (HX-A) is comprisedof a fuel input (3A-IN4) and a combustion products output (3A-OUT2) andis configured to combust the contents of the fuel input (3A-IN4) toindirectly heat the contents within the First Stage Product GasGeneration System (3A) which, in turn, then promotes at least oneendothermic reaction between a portion of the contents of the secondreactor heat transfer medium output (3B-OUT2) to react with thecarbonaceous material (500) to realize a first reactor product gasoutput (3A-OUT1).

FIG. 2:

FIG. 2 shows an embodiment of a three-stage energy integrated productgas generation method. The Product Gas Generation System (3000) of FIG.1 may be configured to employ the use of the three-stage energyintegrated product gas generation method as elaborated upon in FIG. 2.In embodiments, the method steps depicted in FIG. 2 may be used todescribe the embodiment depicted in FIG. 1 showing a three-stage energyintegrated product gas generation system (1001) used as a Product GasGeneration System (3000). The method depicted in FIG. 2 may be used todescribe the operation of the embodiments of a Refinery SuperstructureSystem (RSS) as indicated in FIGS. 1, 3, 24-26 where the Third StageProduct Gas Generation System (3C) cooperates with both the Second StageProduct Gas Generation System (3B) and the First Stage Product GasGeneration System (3A) to realize thermal integration.

FIG. 2 discloses a method for producing a first reactor product gas,second reactor product gas, and third reactor product gas from acarbonaceous material using a First Stage Product Gas Generation System(3A), Second Stage Product Gas Generation System (3B), and a Third StageProduct Gas Generation System (3C) that are thermally integrated withone another and configured for the conversion of carbonaceous materialsinto product gas. FIG. 2 discloses a method for producing a H2, CO, andCO2 from a carbonaceous material using a first reactor, a secondreactor, and a third reactor, the method comprising:

(a) reacting carbonaceous material with a steam reactant in the firstreactor and producing a first reactor product gas containing char;

(b) introducing at least a portion of the char generated in step (a)into the second reactor;

(c) reacting the char of step (b) with an oxygen-containing gas in thesecond reactor and producing a second reactor product gas;

(d) transferring the first reactor product gas generated in step (a) andthe second reactor product gas generated in step (c) to the thirdreactor, to form a combined product gas;

(e) reacting the combined product gas with an oxygen-containing gas inthe third reactor to generate a third reactor product gas and heat;

(f) transferring heat generated in step (e) to a heat transfer mediumcontained within a third reactor heat exchanger in thermal contact withthe interior of the third reactor;

(g) transferring at least some of the heat transfer medium which haspassed through the third reactor heat exchanger, to a second reactorheat exchanger in thermal contact with the interior of the secondreactor;

(h) introducing a first portion of the heat transfer medium which haspassed through the second reactor heat exchanger, into the first reactoras the steam reactant of step (a); and,

(i) introducing a second portion of the heat transfer medium which haspassed through the second reactor heat exchanger, into the secondreactor as a reactant.

FIG. 3:

FIG. 3 shows a simplistic block flow control volume diagram of oneembodiment of a three-stage energy integrated product gas generationsystem (1001) used as a Product Gas Generation System (3000). FIG. 3further shows a simplistic block flow control volume diagram of onenon-limiting embodiment of a three-stage energy integrated product gasgeneration system (1001) including a First Stage Product Gas GenerationControl Volume (CV-3A), a Second Stage Product Gas Generation ControlVolume (CV-3B), and a Third Stage Product Gas Generation Control Volume(CV-3C).

The First Stage Product Gas Generation Control Volume (CV-3A) iscomprised of a First Stage Product Gas Generation System (3A). TheSecond Stage Product Gas Generation Control Volume (CV-3B) is comprisedof a Second Stage Product Gas Generation System (3B). The Third StageProduct Gas Generation Control Volume (CV-3C) is comprised of a ThirdStage Product Gas Generation System (3C). The system (1001) includesFirst Stage Product Gas Generation System (3A) that cooperates with both(i) a downstream Second Stage Product Gas Generation System (3B) and(ii) a downstream Third Stage Product Gas Generation System (3C) toefficiently convert a carbonaceous material into product gas whilesharing heat from upstream endothermic and downstream exothermicreactions.

FIG. 3 further shows a simplistic block flow control volume diagram ofone non-limiting embodiment of a three-stage energy integrated productgas generation system (1001) including a first reactor (100), a firstsolids separation device (150), a second reactor (200), a second solidsseparation device (250), a second reactor heat exchanger (HX-B), a thirdreactor (300), a third reactor heat exchanger (HX-C).

The First Stage Product Gas Generation Control Volume (CV-3A) iscomprised of First Stage Product Gas Generation System (3A) whichincludes a first reactor (100) having a first interior (101). The FirstStage Product Gas Generation Control Volume (CV-3A) has a carbonaceousmaterial input (3A-IN1), a first reactor reactant input (3A-IN2), anoxygen-containing gas input (3A-IN3), a fuel input (3A-IN4), and a firstreactor product gas output (3A-OUT1). The carbonaceous material input(3A-IN1) may be provided from the carbonaceous material output (2-OUT1)of an upstream Feedstock Delivery System (2000) as referenced in FIG. 25and FIG. 26. The first reactor reactant input (3A-IN2) may be providedfrom the second reactor heat transfer medium output (3B-OUT2) of adownstream Second Stage Product Gas Generation System (3B). The fuelinput (3A-IN4) may be provided from a first synthesis hydrocarbon output(7-OUT2) (not shown) of a downstream Synthesis System (7000) asreferenced in FIG. 25 and FIG. 26. The first reactor product gas output(3A-OUT1) transfers the first reactor product gas to the Second StageProduct Gas Generation Control Volume (CV-3B).

The first reactor (100) has a first reactor reactant input (3A-IN2) thatis made available from the Second Stage Product Gas Generation ControlVolume (CV-3B) and configured to provide the heat transfer medium (210)from the outlet (216) of the second reactor heat exchanger (HX-B) foruse as a reactant (106A,106B,106C) in the first reactor (100).

FIG. 3 further illustrates the first reactor (100) having a firstinterior (101) provided with a dense bed zone (AZ-A), a feed zone (AZ-B)above the dense bed zone (AZ-A), and a splash zone (AZ-C) above the feedzone (AZ-B). The carbonaceous material input (3A-IN1) is configured toconvey a carbonaceous material (102) to the feed zone (AZ-B) of thefirst interior (101) of the first reactor (100) via a first reactorcarbonaceous material input (104). The first reactor reactant (106A,106B, 106C) is provided from the outlet (216) of the second reactor heatexchanger (HX-B) and is conveyed to the first reactor (100) via a firstreactor reactant input (3A-IN2) or a second reactor heat transfer mediumoutput (3B-OUT2).

FIG. 3 illustrates the first reactor (100) introducing at least aportion of the heat transfer medium (210) of the second reactor heatexchanger (HX-B) into any combination of the first reactor (100) densebed zone (AZ-A), feed zone (AZ-B), or splash zone (AZ-C) or the secondreactor (200) dense bed zone (BZ-A), feed zone (BZ-B), or splash zone(BZ-C). Thus, in embodiments, the reactant (210) from the second reactorheat exchanger (HX-B) is configured to be introduced to the interior(101) of the first reactor (100) via (i) a first reactor dense bed zonereactant input (108A) as a first reactor dense bed zone reactant (106A),(ii) a first reactor feed zone reactant input (108B) as a first reactorfeed zone reactant (106B), and a (iii) first reactor splash zonereactant input (108C) as a first reactor splash zone reactant (106C).

In the embodiment of FIG. 3, at least a portion of the heat transfermedium (210) of the second reactor heat exchanger (HX-B) may beintroduced into any combination of bed material zones found in eitherthe first reactor (100) or in the second rector (200). In this regard,the first reactor (100) and second reactor (200) can each be consideredto have a dense bend zone formed in the lower portion of the bed region,a feed zone formed in a middle portion of the bed region, and a splashzone formed in the upper portion of the bed region, immediately belowthe freeboard region of either reactor (100, 200). It is understood thatwithin the bed material, the dense bed zone is located below both thefeed and splash zones, the splash zone is located above both the densebed zone and the feed zone, and the feed zone is located between thedense bed zone and the splash zone. It is further understood that forpresent purposes, the boundary between the dense bed zone and the feedzone is the lowest point at which carbonaceous material such as MSW,char, or any other feedstock is introduced into a reactor.

The oxygen-containing gas input (3A-IN3) is configured to convey a firstreactor oxygen-containing gas (118) to the first interior (101) of thefirst reactor (100) via a series of first reactor oxygen-containing gasinputs (120A, 120B, 120C). The first reactor (100) has a first interior(101) provided with a first dense bed zone (AZ-A), a first feed zone(AZ-B) above the first dense bed zone (AZ-A), and a first splash zone(AZ-C) above the first feed zone (AZ-B). Further, in embodiments, theoxygen-containing gas input (3A-IN3) is configured to convey (i) a firstreactor dense bed zone oxygen-containing gas (118A) to a first reactordense bed zone oxygen-containing gas input (120A), (ii) a first reactorfeed zone oxygen-containing gas (118B) to a first reactor feed zoneoxygen-containing gas input (120B), and (iii) a first reactor splashzone oxygen-containing gas (118C) to a first reactor splash zoneoxygen-containing gas input (120C). The first reactor (100) furthercomprises: a first reactor dense bed zone reactant input (108A)configured to introduce a first reactor dense bed zone reactant (106A)to the first dense bed zone (AZ-A); a first reactor feed zone reactantinput (108B) configured to introduce a first reactor feed zone reactant(106B) to the first feed zone (AZ-B); a first reactor splash zonereactant input (108C) configured to introduce a first reactor splashzone reactant (106C) to the first splash zone (AZ-C); a first reactorcarbonaceous material input (104) to the first feed zone (AZ-B); and, afirst reactor product gas output (124) configured to evacuate a firstreactor product gas (122). The first reactor dense bed zone reactantinput (108A), first reactor feed zone reactant input (108B), and thefirst reactor splash zone reactant input (108C), are all in fluidcommunication with the outlet (216) of the second reactor heat exchanger(HX-B).

The first reactor (100) further comprises: a first reactor dense bedzone oxygen-containing gas input (120A) configured to introduce a firstreactor dense bed zone oxygen-containing gas (118A) to the first densebed zone (AZ-A); a first reactor feed zone oxygen-containing gas input(120B) configured to introduce a first reactor feed zoneoxygen-containing gas (118B) to the first feed zone (AZ-B); and, a firstreactor splash zone oxygen-containing gas input (120C) configured tointroduce a first reactor splash zone oxygen-containing gas (118C) tothe first splash zone (AZ-C).

The First Stage Product Gas Generation Control Volume (CV-3A) having aFirst Stage Product Gas Generation System (3A) has a first reactor (100)with a first interior (101) containing a first reactor particulate heattransfer material (105), otherwise referred to as bed material. Inembodiments, the first reactor particulate heat transfer material (105)is comprised of Geldart Group A or Group B solids in the form of inertmaterial, catalyst, sorbent, or engineered particles. The engineeredparticles may be made of alumina, zirconia, sand, olivine sand,limestone, dolomite, or catalytic materials, any of which may be hollowin form, such as microballoons or microspheres. The preferred firstreactor particulate heat transfer material (105) is Geldart Group Balumina microballoons. The first reactor particulate heat transfermaterial (105) enhances mixing, heat and mass transfer, and reactionbetween the carbonaceous material (102) and the reactant (106, 106A,106B, 106C) or oxygen-containing gas (108, 108A, 108B, 108C) introducedto the first reactor (100).

The first interior (101) of the first reactor (100) is configured toaccept a carbonaceous material (102) through a first reactorcarbonaceous material input (104). The first interior (101) of the firstreactor (100) is configured to accept a first reactor reactant (106A,106B, 106C) through a first reactor reactant input (108A, 108B, 108C).The first reactor (100) is configured to thermochemically react thecarbonaceous material (102) with the reactant (106A, 106B, 106C) andoptionally the oxygen-containing gas (118A, 118B, 118C) to generate afirst reactor product gas (122) that is discharged from the firstinterior (101) through a first reactor product gas output (124). A firstreactor product gas (122) is evacuated from the interior (101) of thefirst reactor (100) via a first reactor product gas output (124) fortransfer to the Second Stage Product Gas Generation Control Volume(CV-3B) via a first reactor product gas output (3A-OUT1) or a firstreactor product gas input (3B-IN1).

FIG. 3 depicts the system (1001) including a first reactor first heatexchanger (HX-A1) and a first reactor second heat exchanger (HX-A2) inthermal contact with the first interior (101) of the first reactor(100). FIG. 3 also depicts the First Stage Product Gas GenerationControl Volume (CV-3A) having a First Stage Product Gas GenerationSystem (3A) configured to accept a fuel input (3A-IN4) as a heatexchanger fuel (110) and configured to discharge a combustion stream(114A, 114B). Two first reactor heat exchangers (HX-A1, HX-A2) are shownin FIG. 3 and in embodiments may be immersed in the particulate heattransfer material (105) of the first reactor (100) to provide indirectheat for thermochemical processes taking place within the interior (101)of the first reactor (100).

The first reactor first heat exchanger (HX-A1) is comprised of: a firstreactor first heat exchanger fuel inlet (112A) configured to receive afirst reactor first heat exchanger fuel (110A) at a first inlettemperature (T3A); a first reactor first heat exchanger combustionstream outlet (116A) configured to output a first reactor first heatexchanger combustion stream (114A) at a first outlet temperature (T4A).The first reactor second heat exchanger (HX-A2) is comprised of: a firstreactor second heat exchanger fuel inlet (112B) configured to receive afirst reactor second heat exchanger fuel (110B) at a first inlettemperature (T3B); a first reactor second heat exchanger combustionstream outlet (116B) a configured to output a first reactor second heatexchanger combustion stream (114B) at a first outlet temperature (T4B).

The first reactor first heat exchanger combustion stream (114A) may becombined with the first reactor second heat exchanger combustion stream(114B) (not shown). FIG. 3 also depicts the First Stage Product GasGeneration Control Volume (CV-3A) having a First Stage Product GasGeneration System (3A) configured to accept a fuel input (3A-IN4) as aheat exchanger fuel (110A, 110B) and configured to discharge acombustion products output (3A-OUT2) (not shown) as a combustion stream(114A,114B).

The fuel input (3A-IN4) to the First Stage Product Gas GenerationControl Volume (CV-3A) may be comprised of a mixture of a hydrocarbonand an oxygen-containing gas. FIG. 3 shows an embodiment where thehydrocarbon used in the first reactor heat exchanger fuel (110) may be amethane containing gas such as natural gas, as seen in FIG. 25. Inembodiments, the hydrocarbon used in the first reactor heat exchangerfuel (110A, 110B) may be provided by way of a first synthesishydrocarbon output (7-OUT2) from a downstream Synthesis System (7000),such as tail gas from a Fischer-Tropsch synthesis system, or from amethanol synthesis system, or the like, as seen in FIG. 25 of FIG. 26.In embodiments, the hydrocarbon used in the first reactor heat exchangerfuel (110) may be provided by way of a downstream Upgrading System(8000) such as naphtha, off gas, or the like.

Carbonaceous material (102) enters the First Stage Product GasGeneration System (3A) through a carbonaceous material input (3A-IN1).The first reactor reactant (106A, 106B, 106C) enters the First StageProduct Gas Generation System (3A) and is transferred from the SecondStage Product Gas Generation Control Volume (CV-3B) via a second reactorheat transfer medium output (3B-OUT2). The second reactor heat transfermedium output (3B-OUT2) is configured to transfer the second reactorheat transfer medium (210) from the outlet (216) of the second reactorheat exchanger (HX-B) to the interior (101) of the first reactor (100).FIG. 3 shows the first reactor product gas (122) discharged from theFirst Stage Product Gas Generation System (3A) via a first reactorproduct gas output (3A-OUT1) or a first reactor product gas input(3B-IN1). The first reactor product gas (122) enters the Second StageProduct Gas Generation System (3B) via the first separation input (152)of the first solids separation device (150). The first reactor productgas (122) evacuated from the interior (101) of the first reactor (100)via a first reactor product gas output (124) is transferred to theSecond Stage Product Gas Generation Control Volume (CV-3B). The firstreactor product gas output (124) is in fluid communication with thefirst separation input (152) of the first solids separation device (150)contained within the Stage Product Gas Generation Control Volume(CV-3B).

The second interior (201) of the second reactor (200) is in fluidcommunication with the first interior (101) of the first reactor (100)via a first reactor product gas output (124), first solids separationdevice (150), and second reactor char input (204). Thus, portion of thefirst reactor product gas (122) is separated out in the first solidsseparation device (150) and routed to the interior (201) of the secondreactor (200) via a second reactor char input (204). More specifically,char (202) contained within the first reactor product gas (122) isseparated out in the first solids separation device (150) and routed tothe interior (201) of the second reactor (200) via a second reactor charinput (204).

The Second Stage Product Gas Generation Control Volume (CV-3B) iscomprised of Second Stage Product Gas Generation System (3B) whichincludes a second reactor (200) having a second interior (201) andsecond reactor heat exchanger (HX-B) in thermal contact with theinterior (201) of the second reactor (200). The Second Stage Product GasGeneration Control Volume (CV-3B) also includes a first solidsseparation device (150) and a second solids separation device (250). TheSecond Stage Product Gas Generation Control Volume (CV-3B) is configuredto accept an oxygen-containing gas (218) as an input (3B-IN3) which isin fluid communication with (i) the second reactor dense bed zone (BZ-A)via a second reactor dense bed zone oxygen-containing gas input (220A),(ii) the second reactor feed zone (BZ-B) via a second reactor feed zoneoxygen-containing gas input (220B), and (iii) the second reactor splashzone (BZ-C) via a second reactor splash zone oxygen-containing gas input(220C).

The Second Stage Product Gas Generation Control Volume (CV-3B) isconfigured to accept a portion of the third reactor heat transfer medium(310) from the outlet (316) of the third reactor heat exchanger (HX-C)via a third reactor heat transfer medium output (3C-OUT2) or a secondreactor heat transfer medium input (3B-IN2). The third reactor heattransfer medium (310) transferred from the Third Stage Product GasGeneration Control Volume (CV-3C) to the Second Stage Product GasGeneration Control Volume (CV-3B) is used as a second reactor heattransfer medium (210) inside of the second reactor heat exchanger(HX-B).

The second reactor heat transfer medium inlet (212) is in fluidcommunication with the third reactor heat transfer medium outlet (316).At least a portion of the heat transfer medium (210) from the secondreactor heat exchanger (HX-B) may be transferred into any combination ofthe first reactor (100) dense bed zone (AZ-A), feed zone (AZ-B), orsplash zone (AZ-C) or the second reactor (200) dense bed zone (BZ-A),feed zone (BZ-B), or splash zone (BZ-C). The second reactor dense bedzone reactant input (208A), second reactor feed zone reactant input(208B), and the second reactor splash zone reactant input (208C), areall in fluid communication with the outlet (216) of the second reactorheat exchanger (HX-B).

At least a portion of the third reactor heat transfer medium (310) usedin the third reactor heat exchanger (HX-C) is used as the second reactorheat transfer medium (210) in the reactor heat exchanger (HX-B). Atleast a portion of the second reactor heat transfer medium (210) used inthe reactor heat exchanger (HX-B) is used as a reactant (106A, 106B,106C) in the first reactor (100). A portion of the second reactor heattransfer medium (210) used in the reactor heat exchanger (HX-B) may beused as a reactant (206A, 206B, 206C) in the second reactor (200). Atleast a portion of the third reactor heat transfer medium (310) used inthe third reactor heat exchanger (HX-C) is used as a reactant (106A,106B, 106C) in the first reactor (100). A portion of the third reactorheat transfer medium (310) used in the third reactor heat exchanger(HX-C) is used as a reactant (206A, 206B, 206C) in the second reactor(200).

At least a portion of the third reactor heat transfer medium (310) usedin the third reactor heat exchanger (HX-C) is used as a reactant (106A,106B, 106C) in the first reactor (100) to effectuate at least oneendothermic thermochemical process such as pyrolysis, steam reforming,water gas shift, dry reforming. A portion of the third reactor heattransfer medium (310) used in the third reactor heat exchanger (HX-C) isused as a reactant (206A, 206B, 206C) in the second reactor (200) toeffectuate at least one endothermic thermochemical process such aspyrolysis, steam reforming, water gas shift, dry reforming.

At least a portion of the heat transfer medium (310) used in the thirdreactor heat exchanger (HX-C) is used as the heat transfer medium (210)in the reactor heat exchanger (HX-B) to maintain a second reactortemperature (T-B) within the operating range of 932° F. and 2,552° F. tomaintain a partial oxidation thermochemical process in the secondreactor (200) between a (i) second reactor oxygen-containing gas (218)and (ii) char (202) generated in a first reactor (100) in an endothermicreaction between carbonaceous material (102) and a portion of the thirdreactor heat transfer medium (310) used as a reactant (106A, 106B, 106C)in the first reactor (100).

The Second Stage Product Gas Generation Control Volume (CV-3B) having aSecond Stage Product Gas Generation System (3B) has a second reactor(200) with a second interior (201). The second interior (201) preferablycontains a second reactor particulate heat transfer material (205). Inembodiments, the second reactor particulate heat transfer material (205)is comprised of Geldart Group A or Group B solids in the form of inertmaterial or catalyst or sorbent or engineered particles. The engineeredparticles may be made of alumina, zirconia, sand, olivine sand,limestone, dolomite, or catalytic materials, any of which may be hollowin form, such as microballoons or microspheres. The preferred secondreactor particulate heat transfer material (205) is Geldart Group Balumina microballoons. The second reactor particulate heat transfermaterial (205) enhances mixing, heat and mass transfer, and reactionbetween the char (202) and the reactant or oxygen-containing gasintroduced to the second reactor (200).

The Second Stage Product Gas Generation Control Volume (CV-3B) having aSecond Stage Product Gas Generation System (3B) also has a first solidsseparation device (150). The first solids separation device (150) has: afirst separation input (152) in fluid communication with the firstreactor product gas output (124); a first separation char output (154)in fluid communication with the second reactor char input (204); and afirst separation gas output (156). The second reactor (200) isconfigured to accept a char (202) through a second reactor char input(204) to the second interior (201). The second reactor char input (204)is in fluid communication with the first separation char output (154) ofthe first solids separation device (150) and is configured to conveychar (202) separated from the first reactor product gas (122). Thesecond reactor (200) has a second reactor pressure (P-B) and a secondreactor temperature (T-B).

The first separation char output (154) of the first solids separationdevice (150) is configured to output char (202) and is in fluidcommunication with the second reactor (200) via a second reactor charinput (204). The first separation gas output (156) of the first solidsseparation device (150) is configured to output a char depleted firstreactor product gas (126) via a char depleted first reactor product gasconduit (128). The second reactor (200) is also configured to accept asecond reactor oxygen-containing gas (218A, 218B, 218C) through anynumber of second reactor oxygen-containing gas inputs (220A, 220B, 220C)to the second interior (201).

A second reactor oxygen-containing gas (218) enters the Second StageProduct Gas Generation System (3B) through an oxygen-containing gasinput (3B-IN3). The second reactor (200) is configured to react the char(202) with a second reactor oxygen-containing gas (218, 218A, 218B,218C). The second reactor (200) is also configured to react the char(202) with a reactant (206A, 206B, 206C) provided to the second interior(201) from the outlet (216) of the second reactor heat exchanger (HX-B).

The second reactor (200) is configured to react the char (202) in anexothermic thermochemical process to generate a second reactor productgas (222) that is discharged from the second interior (201) through asecond reactor product gas output (224). The second reactor (200) isconfigured to react char (202) in an endothermic thermochemical processto generate a second reactor product gas (222) that is discharged fromthe second interior (201) through a second reactor product gas output(224). The second reactor (200) is configured to react the char (202) ina combination of exothermic and endothermic thermochemical processes togenerate a second reactor product gas (222) that is discharged from thesecond interior (201) through a second reactor product gas output (224).

The Second Stage Product Gas Generation Control Volume (CV-3B) having aSecond Stage Product Gas Generation System (3B) also has a second solidsseparation device (250). The second solids separation device (250) has:a second separation input (252) in fluid communication with the secondreactor product gas output (224); a second separation solids output(254) in fluid communication with a solids transfer conduit (234); and asecond separation gas output (256) in fluid communication with the chardepleted first reactor product gas conduit (128) or the combined reactorproduct gas conduit (230). The second separation gas output (256) of thesecond solids separation device (250) is configured to output a solidsdepleted second reactor product gas (226) via a solids depleted secondreactor product gas conduit (228). The second separation solids output(254) of the second solids separation device (250) is configured tooutput a second reactor separated solids (232) via a solids transferconduit (234).

The Second Stage Product Gas Generation Control Volume (CV-3B) isconfigured to output both, (i) the char depleted first reactor productgas (126) created by the first reactor (100) and (ii) the solidsdepleted second reactor product gas (226) created by the second reactor(200), to the third reactor (300) within the Third Stage Product GasGeneration Control Volume (CV-3C) via a combined product gas input(3C-IN1) or a product gas output (3B-OUT1). The combined reactor productgas conduit (230) is in fluid communication with both the firstseparation gas output (156) and the second separation gas output (256).The combined reactor product gas conduit (230) is configured to combineproduct gas created by both the first reactor (100) and the secondreactor (200) and route both to the third reactor (300) for conversionin subsequent downstream thermochemical processes. Thus, the product gascreated by both the first reactor (100) and the second reactor (200) aredirected to the third reactor (300) contained within the Third StageProduct Gas Generation System (3C). More specifically, combined reactorproduct gas conduit (230) is in fluid communication with both the chardepleted first reactor product gas conduit (128) and the solids depletedsecond reactor product gas conduit (228) and configured to combine thechar depleted first reactor product gas (126) created by the firstreactor (100) and the solids depleted second reactor product gas (226)created by the second reactor (200). In embodiments, the product gasgenerated in the first reactor (100) and the second reactor (200) arenot combined but are separately and individually transferred to thethird reactor (300).

The char depleted first reactor product gas (126) may pass through arestriction orifice (RO-B) prior to being combined with the solidsdepleted second reactor product gas (226) created by the second reactor(200). In embodiments, the first reactor pressure (P-A) may be greaterthan the second reactor pressure (P-B). In embodiments, the firstreactor pressure (P-A) may be less than the second reactor pressure(P-B). The first reactor (100) has a first reactor pressure (P-A) and afirst reactor temperature (T-A). In embodiments, the first reactortemperature (T-A) may be greater than the second reactor temperature(T-B). In embodiments, the first reactor temperature (T-A) may be lessthan the second reactor temperature (T-B).

A second reactor heat exchanger (HX-B) is in thermal contact with thesecond interior (201) of the second reactor (200). In embodiments, thesecond reactor heat exchanger (HX-B) is immersed beneath the secondreactor particulate heat transfer material (205) within the interior(201) of the second reactor (200). In embodiments, the second reactorheat exchanger (HX-B) is not immersed beneath the second reactorparticulate heat transfer material (205) within the interior (201) ofthe second reactor (200). The second reactor heat exchanger (HX-B)comprises: a second reactor heat transfer medium inlet (212) configuredto receive a heat transfer medium (210) at an inlet temperature (T1);and a second reactor heat transfer medium outlet (216) configured tooutput the heat transfer medium (210), at a higher, outlet temperature(T2). The second reactor heat transfer medium inlet (212) is in fluidcommunication with the third reactor heat transfer medium outlet (316)of the third reactor heat exchanger (HX-C) so as to convey at least aportion of the third reactor heat transfer medium (310) from the thirdreactor heat exchanger (HX-C) to the second reactor heat exchanger(HX-B) for use as the second reactor heat transfer medium (210).

The heat transfer medium (210) enters the Second Stage Product GasGeneration System (3B) from the third reactor heat transfer mediumoutlet (316) via a third reactor heat transfer medium output (3C-OUT2)or a second reactor heat transfer medium input (3B-IN2). The heattransfer medium outlet (316) of the third reactor heat exchanger (HX-C)contained within the Third Stage Product Gas Generation System (3C) isin fluid communication with the inlet (212) of the second reactor heatexchanger (HX-B) within the Second Stage Product Gas Generation System(3B). A second reactor heat transfer medium (210) may in turn bedischarged from the Second Stage Product Gas Generation System (3B) tothe First Stage Product Gas Generation System (3A) via a second reactorheat transfer medium output (3B-OUT2) or a first reactor reactant input(3A-IN2).

The second reactor heat transfer medium outlet (216) on the secondreactor heat exchanger (HX-B) is in fluid communication with thereactant inputs (108A, 108B, 108C) of the first reactor (100) and isconfigured to transfer the second reactor heat transfer medium (210) tothe first reactor (100) for use as a reactant (106A, 106B, 106B) in anycombination of the dense bed zone (AZ-A), feed zone (AZ-B), or splashzone (AZ-C). The second reactor heat transfer medium outlet (216) on thesecond reactor heat exchanger (HX-B) is in fluid communication with thereactant inputs (208A, 208B, 208C) of the second reactor (200) and isconfigured to transfer the second reactor heat transfer medium (210) tothe second reactor (200) for use as a reactant (206A, 206B, 206B) in anycombination of the dense bed zone (BZ-A), feed zone (BZ-B), or splashzone (BZ-C).

FIG. 3 further illustrates the second reactor (200) having a secondinterior (201) provided with a dense bed zone (BZ-A), feed zone (BZ-B)above the dense bed zone (BZ-A), and a splash zone (BZ-C) above the feedzone (BZ-B). Char (202) is fed into the feed zone (BZ-B) of the secondreactor (200). The second reactor (200) further comprises: a secondreactor char input (204) to the feed zone (BZ-B), said second reactorchar input (204) being in fluid communication with the first reactorproduct gas output (124); a second reactor dense bed zone reactant input(208A) configured to introduce a second reactor dense bed zone reactant(206A) to the dense bed zone (BZ-A); a second reactor feed zone reactantinput (208B) configured to introduce a second reactor feed zone reactant(206B) to the feed zone (BZ-B); a second reactor splash zone reactantinput (208C) configured to introduce a second reactor splash zonereactant (206C) to the splash zone (BZ-C); a second reactor dense bedzone oxygen-containing gas input (220A) configured to introduce a secondreactor dense bed zone oxygen-containing gas (218A) to the dense bedzone (BZ-A); a second reactor feed zone oxygen-containing gas input(220B) configured to introduce a second reactor feed zoneoxygen-containing gas (218B) to the feed zone (BZ-B); a second reactorsplash zone oxygen-containing gas input (220C) configured to introduce asecond reactor splash zone oxygen-containing gas (218C) to the splashzone (BZ-C); a second reactor product gas output (224); and, a secondreactor heat exchanger (HX-B) in thermal contact with the secondinterior (201); wherein:

-   -   the second reactor heat exchanger (HX-B) is configured to        receive a heat transfer medium (210) at a second reactor inlet        temperature (T1) and output the heat transfer medium (210), at a        higher, second reactor outlet temperature (T2), via a second        reactor heat transfer medium outlet (216);    -   the second reactor heat transfer medium outlet (216) is        configured to be selectively in fluid communication with any        combination of the first reactor dense bed zone reactant input        (108A), the first reactor feed zone reactant input (108B) and        the first reactor splash zone reactant input (108C); and, the        second reactor heat transfer medium outlet (216) is configured        to be selectively in fluid communication with any combination of        the second reactor dense bed zone reactant input (208A), second        reactor feed zone reactant input (208B) and the second reactor        splash zone reactant input (208C); whereby:    -   at least a portion of the heat transfer medium (210) is capable        of being introduced into any combination of: (i) the        corresponding first reactor dense bed zone (AZ-A), (ii) the        first reactor feed zone (AZ-B), (iii) the first reactor splash        zone (AZ-C), (iv) the corresponding second reactor dense bed        zone (BZ-A), (v) the second reactor feed zone (BZ-B), and, (vi)        the second reactor splash zone (BZ-C).

A portion of the second reactor heat transfer medium (210) istransferred to the first interior (101) of the first reactor (101) at afirst reactor reactant temperature (TR1). In embodiments, the firstreactor reactant temperature (TR1) is about equal to the second reactoroutlet temperature (T2). In embodiments, the first reactor reactanttemperature (TR1) is less than the second reactor outlet temperature(T2) due to heat losses in piping while transferring the heat transfermedium (210) from the outlet (216) of the second reactor heat exchanger(HX-B) to the first interior (101) o the first reactor (100).

The Third Stage Product Gas Generation Control Volume (CV-3C) iscomprised of Third Stage Product Gas Generation System (3C) whichincludes a third reactor (300) having a third interior (301) with athird reactor heat exchanger (HX-C) in thermal contact with the interior(301). The Third Stage Product Gas Generation Control Volume (CV-3C) hasa combined product gas input (304) for accepting the combined productgas (302) including the char depleted first reactor product gas (126)and the solids depleted second reactor product gas (226). The thirdreactor (300) is in fluid communication with the first reactor (100) andthe second reactor (200). More specifically, the combined product gasinput (304) of the third reactor (300) is in fluid communication withthe char depleted first reactor product gas conduit (128) and the solidsdepleted second reactor product gas conduit (228).

The Third Stage Product Gas Generation Control Volume (CV-3C) has acombined product gas input (3C-IN1), a third reactor heat exchanger heattransfer medium input (3C-IN2), an oxygen-containing gas input (3C-IN3),a first hydrocarbon input (3C-IN4), a second hydrocarbon input (3C-IN5),and a third hydrocarbon input (3C-IN6). The combined product gas input(3C-IN1) enters the Third Stage Product Gas Generation System (3C)through a product gas output (3B-OUT1) from the Second Stage Product GasGeneration System (3B). The first hydrocarbon input (3C-IN4) may beprovided from a first synthesis hydrocarbon output (7-OUT2) of adownstream Synthesis System (7000) as referenced in FIG. 25 and FIG. 26.The second hydrocarbon input (3C-IN5) may be provided from a firsthydrocarbon output (8-OUT2) of a downstream Upgrading System (8000) asreferenced in FIG. 25 and FIG. 26. The third hydrocarbon input (3C-IN6)may be provided from a second hydrocarbon output (8-OUT3) of adownstream Upgrading System (8000) as referenced in FIG. 25 and FIG. 26.

The third reactor heat transfer medium (310) that flows through the heattransfer medium input (3C-IN2) is preferably water in the liquid stateor vapor state or a combination of both. In other embodiments, the thirdreactor heat exchanger heat transfer medium can be carbon dioxide,product gas, Fischer-Tropsch tail gas, naphtha, hydrocarbons, nitrogen,air or a combination thereof as appropriate. In some embodiments, carbondioxide can be used as the third reactor heat transfer medium (310),second reactor heat transfer medium (21) and reactant (106, 206).

The third reactor heat transfer medium (310) enters the third reactorheat exchanger (HX-C) via an inlet (312). In embodiments, heat isgenerated from at least one exothermic thermochemical process takingplace within the interior (301) of the third reactor (300) and the heatis transferred through the third reactor heat exchanger (HX-C) into theheat transfer medium (310) contained within the heat exchanger (HX-C).The third reactor heat exchanger (HX-C) is configured to receive a heattransfer medium (310) at a third reactor heat transfer medium inlettemperature T0 and output the heat transfer medium (310) via a thirdreactor heat transfer medium outlet (316). The third reactor heattransfer medium outlet (316) is in fluid communication with the secondreactor heat transfer medium inlet (212) of the second reactor heatexchanger (HX-B) via a third reactor heat transfer medium output(3C-OUT2) or a second reactor heat transfer medium input (3B-IN2).

The oxygen-containing gas input (3C-IN3) is configured to transfer athird reactor oxygen-containing gas (318) to the third reactor (300) viaa third reactor oxygen-containing gas input (320). The first hydrocarboninput (3C-IN4) is configured to transfer a first hydrocarbon stream(322) to the third reactor (300) via a first hydrocarbon stream input(324). In embodiments, the first hydrocarbon stream (322) may be a firstsynthesis hydrocarbon output (7-OUT2), such as tail gas, transferredfrom a downstream Synthesis System (7000) as seen in the RefinerySuperstructure System (RSS) of FIG. 25. The second hydrocarbon input(3C-IN5) is configured to transfer a second hydrocarbon stream (326) tothe third reactor (300) via a second hydrocarbon stream input (328). Inembodiments, the second hydrocarbon stream (326) may be a firsthydrocarbon output (8-OUT2), such as naphtha, transferred from adownstream Upgrading System (8000) as seen in the RefinerySuperstructure System (RSS) of FIG. 25. The third hydrocarbon input(3C-IN6) is configured to transfer a third hydrocarbon stream (330) tothe third reactor (300) via a third hydrocarbon stream input (332). Inembodiments, the third hydrocarbon stream (330) may be a secondhydrocarbon output (8-OUT3), such as off gas, transferred from adownstream Upgrading System (8000) as seen in the RefinerySuperstructure System (RSS) of FIG. 25.

In the embodiment of FIG. 3, the third reactor can be considered to havea combustion zone (CZ-A) in the upper portion of the interior (301) ofthe third reactor (300), a reaction zone (CZ-B) below the combustionzone (CZ-A), a cooling zone (CZ-C) below the reaction zone (CZ-B), and aquench zone (CZ-D) below the cooling zone (CZ-C).

The third reactor (300) has a third reactor pressure (P-C) and a thirdreactor temperature (T-C). In embodiments, the third reactor pressure(P-C) may be greater than the first reactor pressure (P-A). Inembodiments, the third reactor pressure (P-C) may be less than the firstreactor pressure (P-A). In embodiments, the third reactor pressure (P-C)may be greater than the second reactor pressure (P-B). In embodiments,the third reactor pressure (P-C) may be less than the second reactorpressure (P-B). In embodiments, the third reactor temperature (T-C) maybe greater than the first reactor temperature (T-A). In embodiments, thethird reactor temperature (T-C) may be less than the first reactortemperature (T-A). In embodiments, the third reactor temperature (T-C)may be greater than the second reactor temperature (T-B). Inembodiments, the third reactor temperature (T-C) may be less than thesecond reactor temperature (T-B).

In embodiments, the third reactor may operate in an exothermic mode. Inembodiments, the third reactor may operate in an exothermic mode in anon-catalytic environment. In embodiments, the third reactor may operatein an exothermic mode in a catalytic environment. In embodiments, thethird reactor may operate in an endothermic mode. In embodiments, thethird reactor may operate in an endothermic mode in a catalyticenvironment. In embodiments, the third reactor may operate in anendothermic mode in a non-catalytic environment.

The Third Stage Product Gas Generation Control Volume (CV-3C) isconfigured to generate a third reactor product gas (334) that isevacuated from the interior (301) of the third reactor (300) via a thirdreactor product gas output (336) or a third reactor product gas output(3C-OUT1). The third reactor product gas output (3C-OUT1) as seen inFIG. 3 may also be made available to a downstream Primary Gas Clean UpSystem (4000) as a product gas input (4-IN1) as displayed in FIG. 25 andFIG. 26. The Third Stage Product Gas Generation Control Volume (CV-3C)is configured to output slag (338) that is evacuated from the interior(301) of the third reactor (300) via a third reactor slag output (340)or a solids output (3C-OUT3). In one non-limiting embodiment, FIG. 3shows the third reactor (300) configured to accept product gas from thefirst reactor (100) and second reactor (200), along with a third reactoroxygen-containing gas (318), and optionally a hydrocarbon (322, 326,330), and thermochemically react a portion thereof in an exothermicreaction to generate heat and product gas. In response, a third reactorheat exchanger (HX-C) is configured to transfer heat generated in thethird reactor (300) to a heat transfer medium (310) for use as a heattransfer medium (210) in the second reactor heat exchanger (HX-B). Thesecond reactor heat exchanger (HX-B) is configured to transfer heat fromthe second reactor (200) to a heat transfer medium (210) for use as areactant (106A, 106B, 106C) in the first reactor (100) or the secondreactor (200), or both the first reactor (100) and the second reactor(200).

In embodiments, water in the liquid or vapor form are used as the thirdreactor heat transfer medium (310). In embodiments, water in the liquidor vapor form are used as the second reactor heat transfer medium (210).In embodiments, the second reactor heat transfer medium (210) dischargedfrom the outlet (216) of the second reactor heat exchanger (HX-B) andtransferred as a reactant (106A, 106B, 106C) to the first reactor (100)is superheated steam. In embodiments, the second reactor heat transfermedium (210) discharged from the outlet (216) of the second reactor heatexchanger (HX-B) and transferred as a reactant (206A, 206B, 206C) to thesecond reactor (200) is superheated steam.

In embodiments, carbon dioxide or product gas is used as the thirdreactor heat transfer medium (310). In embodiments, carbon dioxide orproduct gas is used as the third reactor heat transfer medium (310). Inthe embodiment of FIG. 3, the heat transfer medium (310) transferredfrom the outlet (316) of the third reactor heat exchanger (HX-C) to theinlet (212) of the second reactor heat exchanger (HX-B) is steam. In theembodiment of FIG. 3, the heat transfer medium (310) transferred fromthe outlet (316) of the third reactor heat exchanger (HX-C) to the inlet(212) of the second reactor heat exchanger (HX-B) and from the outlet(216) of the second reactor heat exchanger (HX-B) to the interior (101)of the first reactor (100) is steam. However, the heat transfer medium(310) transferred from the outlet (316) of the third reactor heatexchanger (HX-C) to the inlet (212) of the second reactor heat exchanger(HX-B) and from the outlet (216) of the second reactor heat exchanger(HX-B) to the interior (101) of the first reactor (100) may be water inthe liquid state or vapor state or a combination of both. Inembodiments, the third reactor heat transfer medium (310) can be water,carbon dioxide, product gas, Fischer-Tropsch tail gas, naphtha,hydrocarbons, nitrogen, air or a combination thereof as appropriate.

FIG. 4:

FIG. 4 elaborates upon the non-limiting embodiment of FIG. 3 howevershows the third reactor (300) having both a first reactor product gasinput (303) and a second reactor product gas input (305) as opposed toonly one combined product gas input (304), as depicted in FIG. 3. Asdisplayed in FIG. 4, the product gas generated in the first reactor(100) and the second reactor (200) are not combined but are separatelyand individually transferred to the third reactor (300). The firstreactor product gas input (303) on the third reactor (300) is in fluidcommunication with the first separation gas output (156) to permit achar depleted first reactor product gas (126) to flow through the chardepleted first reactor product gas conduit (128) and into the thirdinterior (301). The second reactor product gas input (305) on the thirdreactor (300) is in fluid communication with the second separation gasoutput (256) to permit a solids depleted second reactor product gas(226) to flow through the solids depleted second reactor product gasconduit (228) and into the third interior (301).

FIG. 5:

FIG. 5 elaborates upon the non-limiting embodiment of FIG. 3 furtherincluding an auxiliary heat exchanger (HX-2) configured to transfer heatfrom a combustion stream (114) to an auxiliary heat exchanger heattransfer medium (164) that is fluid communication with the heat transfermedium inlet (212) of the second reactor heat exchanger (HX-B) via aexchanger heat transfer medium outlet conduit (170). FIG. 5 shows acombined combustion stream (114) exiting the First Stage Product GasGeneration System (3A) through a combustion products output (3A-OUT2)and entering the Second Stage Product Gas Generation System (3B) througha combustion products input (3B-IN6). Connection X0 indicates thecombined combustion stream (114) entering the Second Stage Product GasGeneration Control Volume (CV-3B) en route to the auxiliary heatexchanger (HX-2).

Note that FIG. 5 only shows one first reactor heat exchanger (HX-A) asopposed to FIG. 3 where both, a first heat exchanger (HX-A1) and asecond heat exchanger (HX-A2) are shown. Irrespective as to how manyheat exchangers are contained within the interior (101) of the firstreactor (100), any suitable configuration is suitable so long as theauxiliary heat exchanger (HX-2) may accept one or more of the combinedcombustion streams (114, 114A, 114B, 114C, 114D) from any number of heatexchanger combustion stream outlets (116, 116A, 116B, 116C, 116D) fromany number of first reactor heat exchangers (HX-A, HX-A1, HX-A2, HX-A3,HX-A4). Notwithstanding the quantity of first reactor heat exchangers(HX-A, HX-A1, HX-A2), FIG. 5 depicts the system (1001) according to FIG.3, further comprising: an auxiliary heat exchanger (HX-2) external tothe first reactor (100) and in thermal contact with a first reactor heatexchanger combustion stream (114) exiting the heat exchanger combustionstream outlet (116); wherein the auxiliary heat exchanger (HX-2) isconfigured to transfer heat from the combustion stream (114) to anauxiliary heat exchanger heat transfer medium (164) which exits theauxiliary heat exchanger (HX-2) via auxiliary heat exchanger heattransfer medium outlet conduit (170).

An auxiliary heat exchanger (HX-2) has an auxiliary heat exchanger heattransfer medium (164) in thermal contact with the combustion stream(114) exiting the first heat exchanger (HX-A). The auxiliary heatexchanger (HX-2) is comprised of: an auxiliary heat exchanger heattransfer medium inlet (166) configured to receive an auxiliary heatexchanger heat transfer medium (164) at a first inlet temperature (T6);and an auxiliary heat exchanger heat transfer medium outlet (168)configured to output the heat transfer medium (164), at a higher, secondoutlet temperature (T7). The auxiliary heat exchanger (HX-2) is alsocomprised of: a combustion stream inlet (160) configured to receive acombustion stream (114) at a third inlet temperature (T4); and acombustion stream outlet (167) configured to output a combustion stream(114), at a lower, fourth outlet temperature (T5). (T3) is synonymouswith the first reactor heat exchanger fuel inlet temperature (T3). (T4)is synonymous with the first reactor heat exchanger combined combustionstream outlet temperature (T4). Connection X0 shows the combustionstream (114) exiting the first heat exchanger (HX-A) within the FirstStage Product Gas Generation Control Volume (CV-3A) and entering theauxiliary heat exchanger (HX-2) contained within the Second StageProduct Gas Generation Control Volume (CV-3B).

In embodiments, the auxiliary heat exchanger heat transfer medium outletconduit (170) routes the heat transfer medium (164) at the second outlettemperature (T7) to a second reactor combined heat transfer mediumconduit (174) to be used as the heat transfer medium (210) for thesecond reactor heat exchanger (HX-B).

The first reactor auxiliary heat exchanger heat transfer medium outlet(168) is in fluid communication with the second reactor heat transfermedium inlet (212) of the second reactor heat exchanger (HX-B) via anauxiliary heat exchanger heat transfer medium outlet conduit (170), tothereby supply the auxiliary heat exchanger heat transfer medium (164)as a heat transfer medium (210) for the second reactor heat exchanger(HX-B), and ultimately as a portion of the reactant (106) in the firstreactor (100) and also as a portion of the reactant (206) used in thesecond reactor (200).

FIG. 6:

FIG. 6 elaborates upon the non-limiting embodiment of FIG. 5 where aportion of the third reactor heat transfer medium (310) is transferredfrom the outlet (316) of the third reactor heat exchanger (HX-C) to theinlet (166) of the auxiliary heat exchanger (HX-2) for use as theauxiliary heat exchanger heat transfer medium (164). In embodiments, thethird reactor heat transfer medium (310) may come into thermal contactwith the combustion stream (114) prior to being introduced to the inlet(212) of the second reactor heat exchanger (HX-B). Accordingly, thethird reactor heat transfer medium (310) may have an inlet temperature(T6) to the auxiliary heat exchanger (HX-2) that is less than the outlettemperature (T7) of the auxiliary heat exchanger (HX-2). Connection X1shows the combustion stream (114) exiting the first reactor heatexchanger (HX-A) within the First Stage Product Gas Generation ControlVolume (CV-3A) and entering the auxiliary heat exchanger (HX-2)contained within the Second Stage Product Gas Generation Control Volume(CV-3B).

FIG. 6 displays the outlet (316) of the third reactor heat exchanger(HX-C) being in fluid communication with the inlet (212) of the secondreactor heat exchanger (HX-B) with an auxiliary heat exchanger (HX-2),and a steam turbine (172) interposed therebetween. The third reactorheat transfer medium (310) may become superheated by the combustionstream (114) in the auxiliary heat exchanger (HX-2) prior to beingrouted to the steam turbine (172). A steam turbine (172) may bepositioned in the conduit (171) in between the outlet (168) of theauxiliary heat exchanger (HX-2) and the inlet (212) of the secondreactor heat exchanger (HX-B).

In embodiments, water may be used as the third reactor heat transfermedium (310). FIG. 6 shows water as the third reactor heat transfermedium (310) and introduced to the inlet (312) of the third reactor heatexchanger (HX-C). The water used as the third reactor heat transfermedium (310), and introduced to the inlet (312) of the third reactorheat exchanger (HX-C) may be in the liquid phase. However, in someembodiments, the water used as the third reactor heat transfer medium(310), and introduced to the inlet (312) of the third reactor heatexchanger (HX-C) may be in the liquid and vapor phase. In someembodiments, the water used as the third reactor heat transfer medium(310), and introduced to the inlet (312) of the third reactor heatexchanger (HX-C) is in the vapor phase.

As a result of at least one exothermic thermochemical process orreaction taking place within the interior (301) of the third reactor(300), heat is transferred from the interior (301) of the third reactor(300), through the third reactor heat exchanger (HX-C), and into thewater heat transfer medium (310) contained within the third reactor heatexchanger (HX-C). As a result, steam is discharged from the outlet (316)of the third reactor heat exchanger (HX-C) and subsequently introducedto the inlet (166) of the auxiliary heat exchanger (HX-2).

Heat is transferred from the combustion stream (114), through theauxiliary heat exchanger (HX-2), and into the heat transfer medium (310)contained within the auxiliary heat exchanger (HX-2). As a result of theindirect contact between a portion of the third reactor heat transfermedium (310) and the combustion stream (114), superheated steam isdischarged from the heat transfer medium outlet (168) of the auxiliaryheat exchanger (HX-2).

A steam turbine (172) with an integrated generator (173) may beconfigured to accept the superheated heat transfer medium (310)discharged from the auxiliary heat exchanger (HX-2) to produce power(175). A portion of the third reactor heat transfer medium (310) may befurther transferred to the inlet (212) of the second reactor heatexchanger (HX-B) for eventual use as a reactant (160, 106A, 106B, 106C)in the first reactor (100) or as a reactant (206, 206A, 206B, 206C) inthe second reactor (200). The embodiment of FIG. 6 enables in-situ powergeneration via a steam turbine (172) and integrated generator (173) tosatisfy the power demand of the Refinery Superstructure System (RSS) asdepicted in FIGS. 25 and 26.

FIG. 7:

FIG. 7 is a detailed view of FIG. 3 showing a non-limiting embodiment ofa First Stage Product Gas Generation Control Volume (CV-3A) and FirstStage Product Gas Generation System (3A) of a three-stageenergy-integrated product gas generation system (1001) including a firstreactor (100) equipped with a dense bed zone (AZ-A), feed zone (AZ-B),and splash zone (AZ-C), along with the first reactor carbonaceousmaterial input (104), valves, sensors, and controllers.

FIG. 7 shows a first reactor (100) having a first interior (101)provided with a first dense bed zone (AZ-A), a first feed zone (AZ-B)above the first dense bed zone (AZ-A), and a first splash zone (AZ-C)above the first feed zone (AZ-B). The first splash zone (AZ-C) isproximate to the first fluid bed level (L-A) and below the firstfreeboard zone (FB-A). In embodiments, the dense bed zone (AZ-A)corresponds to the lower portion of the dense bed within the firstinterior (101). In embodiments, the feed zone (AZ-B) is located abovethe dense bed zone (AZ-A). In embodiments, the splash zone (AZ-C) may belocated above the feed zone (AZ-B) and below the first fluid bed level(L-A).

The system (1001) according to FIG. 7, comprises four first reactor heatexchangers (HX-A1, HX-A2, HX-A3, HX-A4) in thermal contact with thefirst interior (101) of the first reactor (100). The four first reactorheat exchangers (HX-A1, HX-A2, HX-A3, HX-A4) are positioned in the firstinterior (101) and vertically spaced apart from one another along theheight dimension of the first interior (101).

The first reactor first heat exchanger (HX-A1) is comprised of: a firstreactor first heat exchanger fuel inlet (112A) configured to introduce afirst reactor first heat exchanger fuel (110A) at a first inlettemperature (T3A); and a first reactor first heat exchanger combustionstream outlet (116A) configured to discharge a first reactor first heatexchanger combustion stream (114A) at a higher, second outlettemperature (T4A).

The first reactor third heat exchanger (HX-A3) is comprised of: a firstreactor third heat exchanger fuel inlet (112C) configured to introduce afirst reactor third heat exchanger fuel (110C) at a first inlettemperature (T3C); and a first reactor third heat exchanger combustionstream outlet (116C) configured to discharge a first reactor third heatexchanger combustion stream (114C) at a higher, second outlettemperature (T4C).

Connection X2 shows the first reactor first heat exchanger combustionstream (114A) being routed to be combined with the discharge of thefirst reactor third heat exchanger combustion stream (114C) from thefirst reactor third heat exchanger combustion stream outlet (116C) ofthe first reactor first heat exchanger (HX-A1) to form a combinedcombustion stream (114).

FIG. 7 further depicts the First Stage Product Gas Generation ControlVolume (CV-3A) having a First Stage Product Gas Generation System (3A)configured to accept a fuel input (3A-IN4) as a heat exchanger fuel(110, 110A, 110B, 110C, 110D) for the four first reactor heat exchangers(HX-A1, HX-A2, HX-A3, HX-A4). Each first reactor heat exchangers (HX-A1,HX-A2, HX-A3, HX-A4) is shown in be in physical contact with the firstreactor particulate heat transfer material (105) and configured todischarge a combustion products output (3A-OUT2) as a combustion stream(114). The combustion products output (3A-OUT2) may be routed to anauxiliary heat exchanger (HX-2) as a combustion products input (3B-IN6)as depicted in FIGS. 5 and 6.

The embodiment of FIG. 7 shows the heat of reaction is supplied to thebed material (104) of the first reactor (100) indirectly by heatexchangers (HX-A1, HX-A3) such as pulse combustion device. Any type ofheat exchanger may be used, such as pulse heater tailpipes, electricalheater rods in thermowells, fuel cells, heat pipes, fire-tubes,annulus-type heat exchangers, or radiant tubes. The embodiment of FIG. 7also shows the heat of reaction also being supplied to the bed material(105) of the first reactor (100) directly by utilization of a fuel(3A-IN4) such as a mixture of hydrocarbons and an oxygen-containing gas.A portion of the product gas may be supplied as fuel (110) to the pulsecombustion devices and combustion of these gases provides the heatnecessary for the indirect endothermic thermochemical processes takingplace within the first interior (101) of the first reactor (100). In oneembodiment, the heat exchangers (HX-A1, HX-A3) may be a pulse combustiondevice that combusts a source of fuel (110) to form a pulse combustionstream (114) comprising flue gas. The pulse combustion stream (114)indirectly heats the particulate bed material (105) of the first reactor(100). As used therein, indirectly heating the bed means that the pulsecombustion stream (114) does not contact the contents of the bedmaterial (105) of the first reactor (100).

In some embodiments, the combustion of the fuel and oxygen-containinggas contained in the first reactor heat exchanger fuel (110) takes placewithin the first reactor heat exchangers (HX-A1, HX-A3). As a result,the first reactor heat exchanger fuel inlet temperature (T3) will beless than the first reactor heat exchanger combined combustion streamoutlet temperature (T4). In some embodiments, the combustion of the fueland oxygen-containing gas contained in the first reactor heat exchangerfuel (110) takes place outside of and prior to entering the firstreactor heat exchangers (HX-A1, HX-A3). As a result, the first reactorheat exchanger combined combustion stream outlet temperature (T4) willbe less than the first reactor heat exchanger fuel inlet temperature(T3). Heat exchangers for transferring thermal energy to a particulateheat transfer material (105) contained within the interior (101) of afirst reactor are well known in the art and as such the details anddesign are not particularly relevant here.

In embodiments, the first reactor particulate heat transfer material(105) is comprised of Geldart Group A or Group B solids in the form ofinert material or catalyst or sorbent or engineered particles. Theengineered particles may be made of alumina, zirconia, sand, olivinesand, limestone, dolomite, or catalytic materials, any of which may behollow in form, such as microballoons or microspheres. The preferredfirst reactor particulate heat transfer material (105) is Geldart GroupB alumina microballons. The first reactor particulate heat transfermaterial (105) enhances mixing, heat and mass transfer, and reactionbetween the carbonaceous material (102) and the reactant oroxygen-containing gas introduced to the first reactor (100).

A carbonaceous material input (3A-IN1) is introduced to the First StageProduct Gas Generation Control Volume (CV-3A) as a first reactorcarbonaceous material input (104) and is configured to provide acarbonaceous material (102) to the feed zone (AZ-B) of the first reactor(100).

A carbonaceous material (102) is introduced to the interior (101) of thefirst reactor (100) for intimate contact with the heated particulateheat transfer material (105), reactant (106, 106A, 106B, 106C) andoxygen-containing gas (218, 218A, 218B, 218C) to produce a first reactorproduct gas (122) that is discharged from the interior (101) of thefirst reactor (100) via a first reactor product gas output (124).

The first reactor product gas output (124) exits the First Stage ProductGas Generation Control Volume (CV-3A) through a first reactor productgas output (3A-OUT1) and enters the Second Stage Product Gas GenerationControl Volume (CV-3B) shown in FIG. 13 as a first reactor product gasinput (3B-IN1).

FIG. 7 depicts steam being introduced to the First Stage Product GasGeneration Control Volume (CV-3A) as a reactant (106) via a firstreactor reactant input (3A-IN2) or a second reactor heat transfer mediumoutput (3B-OUT2) to be made available to any combination of (i) thecorresponding first reactor dense bed zone (AZ-A), (ii) the firstreactor feed zone (AZ-B), and (iii) the first reactor splash zone(AZ-C). The reactant (106) is at a first reactor reactant temperature(TR1).

Further, FIG. 7 depicts an oxygen-containing gas (118) being introducedto the First Stage Product Gas Generation Control Volume (CV-3A) throughan oxygen-containing gas input (3A-IN3) to be made available to anycombination of (i) the corresponding first reactor dense bed zone(AZ-A), (ii) the first reactor feed zone (AZ-B), and (iii) the firstreactor splash zone (AZ-C).

FIG. 7 depicts the system (1001) further including: a first reactordense bed zone reactant input (108A) and first reactor dense bed zoneoxygen-containing gas input (120A) in fluid communication with a densebed zone steam/oxygen connection (AZA0). The dense bed zone steam/oxygenconnection (AZA0) is in fluid communication with the dense bed zonesteam/oxygen input (AZA2) and is configured to transport the dense bedzone steam/oxygen (AZA1) to the first reactor (100) dense bed zone(AZ-A). The first reactor (100) dense bed zone steam/oxygen (AZA1) is amixture of the first reactor dense bed zone reactant (106A) and firstreactor dense bed zone oxygen-containing gas (118A).

A first reactor dense bed zone reactant valve (VA1), configured toaccept a signal (XA1) from a controller (CA1), is installed upstream ofthe input (108A) to control the amount of reactant (106A) supplied tothe first reactor (100) dense bed zone (AZ-A). A first reactor dense bedzone oxygen-containing gas valve (VA2), configured to accept a signal(XA2) from a controller (CA2), is installed upstream of the input (120A)to control the amount of oxygen-containing gas (118A) supplied to thefirst reactor (100) dense bed zone (AZ-A).

FIG. 7 depicts the system (1001) further including: a first reactor feedzone reactant input (108B) and first reactor feed zone oxygen-containinggas input (120B) in fluid communication with a feed zone steam/oxygenconnection (AZB0). The feed zone steam/oxygen connection (AZB0) is influid communication with the feed zone steam/oxygen input (AZB2) andconfigured to transport the feed zone steam/oxygen (AZB1) to the firstreactor (100) feed zone (AZ-B). The first reactor (100) feed zonesteam/oxygen (AZB1) is a mixture of the first reactor feed zone reactant(106B) and first reactor feed zone oxygen-containing gas (118B).

A first reactor feed zone reactant valve (VA3), configured to accept asignal (XA3) from a controller (CA3), is installed upstream of the input(108B) to control the amount of reactant (106B) supplied to the firstreactor (100) feed zone (AZ-B). A first reactor feed zoneoxygen-containing gas valve (VA4), configured to accept a signal (XA4)from a controller (CA4), is installed upstream of the input (120B) tocontrol the amount of oxygen-containing gas (118B) supplied to the firstreactor (100) feed zone (AZ-B).

FIG. 7 depicts the system (1001) further including: a first reactorsplash zone reactant input (108C) and first reactor splash zoneoxygen-containing gas input (120C) in fluid communication with a splashzone steam/oxygen connection (AZC0). The splash zone steam/oxygenconnection (AZC0) is in fluid communication with the splash zonesteam/oxygen input (AZC2) and configured to transport the splash zonesteam/oxygen (AZC1) to the first reactor (100) splash zone (AZ-C). Thefirst reactor (100) splash zone steam/oxygen (AZC1) is a mixture of thefirst reactor splash zone reactant (106C) and first reactor splash zoneoxygen-containing gas (118C).

A first reactor splash zone reactant valve (VA5), configured to accept asignal (XA5) from a controller (CA5) is installed upstream of the input(108C) to control the amount of reactant (106C) supplied to the firstreactor (100) splash zone (AZ-C). A first reactor splash zoneoxygen-containing gas valve (VA6), configured to accept a signal (XA6)from a controller (CA6) is installed upstream of the input (120C) tocontrol the amount of oxygen-containing gas (118C) supplied to the firstreactor (100) splash zone (AZ-C). An internal cyclone (125) is shown inthe freeboard zone (FB-A) of the first reactor (100).

FIG. 8:

FIG. 8 elaborates upon the non-limiting embodiment of FIG. 7 furtherincluding multiple carbonaceous material inputs (104A, 104B, 104C, 104D)and multiple feed zone steam/oxygen inputs (AZB2, AZB3, AZB4, AZB5)positioned in the feed zone (AZ-B) along with multiple splash zonesteam/oxygen inputs (AZC2, AZC3, AZC4, AZC5) positioned in the splashzone (AZ-C). FIG. 8 depicts four carbonaceous material inputs (104A,104B, 104C, 104D) to the feed zone (AZ-B) of the first interior (101) ofthe first reactor (100). Each carbonaceous material input (104A, 104B,104C, 104D) has a corresponding steam/oxygen input (AZB2, AZB3, AZB4,AZB5).

Specifically, the first reactor first carbonaceous material input (104A)has its own source of feed zone steam/oxygen (AZB1) introduced from thefirst feed zone steam/oxygen input (AZB2). The second carbonaceousmaterial input (104B) has its own source of feed zone steam/oxygen(AZB1) introduced from the second feed zone steam/oxygen input (AZB3).The third carbonaceous material input (104C) has its own source of feedzone steam/oxygen (AZB1) introduced from the third feed zonesteam/oxygen input (AZB4). The fourth carbonaceous material input (104D)has its own source of feed zone steam/oxygen (AZB1) introduced from thefourth feed zone steam/oxygen input (AZB5). Connection X3 indicates thefeed zone steam/oxygen (AZB1) being introduced to the third feed zonesteam/oxygen input (AZB4) and the fourth feed zone steam/oxygen input(AZB5). Connection X4 indicates carbonaceous material (102C and 102D)being introduced to a third carbonaceous material input (104C) and afourth carbonaceous material input (104D), respectively.

FIG. 8 depicts four splash zone steam/oxygen inputs (AZC2, AZC3, AZC4,AZC5) to the splash zone (AZ-C) of the first interior (101) of the firstreactor (100). Each of the four splash zone steam/oxygen inputs (AZC2,AZC3, AZC4, AZC5) is fed from a common source of splash zonesteam/oxygen (AZC1) for delivery to the splash zone (AZ-C) of the firstinterior (101) of the first reactor (100). Connection X5 indicates thesplash zone steam/oxygen (AZC1) being introduced to the second splashzone steam/oxygen input (AZC3), third splash zone steam/oxygen input(AZC4), and the fourth splash zone steam/oxygen input (AZC5). ConnectionX6 indicates the splash zone steam/oxygen (AZC1) being introduced to thesecond splash zone steam/oxygen input (AZC3). Note that although onlyfour carbonaceous material inputs (104A, 104B, 104C, 104D) it ispreferred to have six inputs as later indicated in FIG. 9 and FIG. 10.

FIG. 8 also shows the perspective of a first reactor feed zonecross-sectional view (XAZ-B) that will be elaborated upon in FIGS. 9,10, and 11. FIG. 8 also shows the perspective of a first reactor splashzone cross-sectional view (XAZ-C) that will be elaborated upon in FIG.12.

FIG. 8 also shows the first reactor first carbonaceous material input(104A) and the first reactor second carbonaceous material input (104B)introduced to the interior (101) of the first reactor at differentplanes at different vertical heights about the first reactor (100). FIG.8 also shows the first reactor third carbonaceous material input (104C)and the first reactor fourth carbonaceous material input (104D)introduced to the interior (101) of the first reactor at differentplanes at different vertical heights about the first reactor (100).

FIG. 9:

FIG. 9 shows a non-limiting embodiment of a first reactor feed zonecross-sectional view (XAZ-B) from the embodiment of FIG. 8. Inembodiments, six carbonaceous material inputs (104A, 104B, 104C, 104D,104E, 104F) are positioned about the circumference of the first reactor(100). FIG. 9 also depicts each of the six carbonaceous material inputs(104A, 104B, 104C, 104D, 104E, 104F) having its own dedicated source offeed zone steam/oxygen introduced through a respective feed zonesteam/oxygen input (AZB2, AZB3, AZB4, AZB5, AZB6). The first feed zonesteam/oxygen input (AZB2) has a first reactor first carbonaceousmaterial input (104A). The first reactor second carbonaceous materialinput (104B) has a second feed zone steam/oxygen input (AZB3). The firstreactor third carbonaceous material input (104C) has a third feed zonesteam/oxygen input (AZB4). The first reactor fourth carbonaceousmaterial input (104D) has a fourth feed zone steam/oxygen input (AZB5).The first reactor fifth carbonaceous material input (104E) has a fifthfeed zone steam/oxygen input (AZB6). The first reactor sixthcarbonaceous material input (104F) has a sixth feed zone steam/oxygeninput (AZB7).

Four of the six carbonaceous material inputs (104A, 104C, 104D, 104F)are positioned 90 degrees from one another. Two of the six carbonaceousmaterial inputs (104B, 104E) are positioned 180 degrees from one anotherat angles of 45 degrees and 225 degrees leaving the angled positions of135 degrees and 315 degrees vacant where the angle 0 degrees and 360degrees are at the twelve-o-clock position on the circular diagramdepicting the first reactor (100).

FIG. 10:

FIG. 10 shows a non-limiting embodiment of a first reactor feed zonecross-sectional view (XAZ-B) from the embodiment of FIG. 8, however,FIG. 10 shows a rectangular first reactor (100) cross-sectional view. Inembodiments, six carbonaceous material inputs (104A, 104B, 104C, 104D,104E, 104F) are positioned about the perimeter of the first reactor(100).

Similar to FIG. 9, FIG. 10 shown each of the six carbonaceous materialinputs (104A, 104B, 104C, 104D, 104E, 104F) having its own dedicatedsource of feed zone steam/oxygen introduced through a respective feedzone steam/oxygen input (AZB2, AZB3, AZB4, AZB5, AZB6). The first feedzone steam/oxygen input (AZB2) has a first reactor first carbonaceousmaterial input (104A). The first reactor second carbonaceous materialinput (104B) has a second feed zone steam/oxygen input (AZB3). The firstreactor third carbonaceous material input (104C) has a third feed zonesteam/oxygen input (AZB4). The first reactor fourth carbonaceousmaterial input (104D) has a fourth feed zone steam/oxygen input (AZB5).The first reactor fifth carbonaceous material input (104E) has a fifthfeed zone steam/oxygen input (AZB6). The first reactor sixthcarbonaceous material input (104F) has a sixth feed zone steam/oxygeninput (AZB7).

FIG. 11:

FIG. 11 shows a non-limiting embodiment of a first reactor feed zonecross-sectional view (XAZ-B) from the embodiment of FIG. 8 where onlytwo of the six first reactor (100) carbonaceous material inputs (104B,104E) are configured to inject carbonaceous material into verticallyextending quadrants (Q1, Q2, Q3, Q4). FIG. 11 elaborates upon thepreference to have only two of the six first reactor carbonaceousmaterial inputs (104B, 104E) configured to inject carbonaceous materialinto the vertically extending quadrants (Q1, Q3). Further, each of thesix carbonaceous material inputs (104A, 104B, 104C, 104D, 104E, 104F)has its own dedicated steam/oxygen input (AZB2, AZB3, AZB4, AZB5, AZB6,AZB7), respectfully. FIG. 11 depicts four first reactor heat exchangers(HX-A1, HX-A2, HX-A3, HX-A4) positioned in the first interior (101) andvertically spaced apart from one another along the height dimension ofthe first interior; wherein: alternate first reactor heat exchangersalong said first height dimension are arranged orthogonal to one anothersuch that, in a top view of the first interior, the four first reactorheat exchangers define four open vertically extending quadrants (Q1, Q2,Q3, Q4).

FIG. 12:

FIG. 12 shows a non-limiting embodiment of a first reactor splash zonecross-sectional view (XAZ-C) from the embodiment of FIG. 8. Inembodiments, eight separate splash zone steam/oxygen inputs (AZC2, AZC3,AZC4, AZC5, AZC6, AZC7, AZC8, AZC9) are shown equidistantly spaced apartat 45 degree angles to one another about the circumference of the firstreactor (100). Each of the eight separate splash zone steam/oxygeninputs (AZC2, AZC3, AZC4, AZC5, AZC6, AZC7, AZC8, AZC9) accepts a sourceof splash zone steam/oxygen (AZC1).

FIG. 13:

FIG. 13 is a detailed view of FIG. 3 showing a non-limiting embodimentof a Second Stage Product Gas Generation Control Volume (CV-3B) andSecond Stage Product Gas Generation System (3B) of a three-stageenergy-integrated product gas generation system (1001) including asecond reactor (200) equipped with a dense bed zone (BZ-A), feed zone(BZ-B), and splash zone (BZ-C), along with a second reactor heatexchanger (HX-B), first solids separation device (150), second solidsseparation device (250), solids flow regulator (245), riser (236),dipleg (244), and valves, sensors, and controllers.

FIG. 13 shows a second reactor (200) having a second interior (201)provided with a dense bed zone (BZ-A), a feed zone (BZ-B) above thedense bed zone (BZ-A), and a splash zone (BZ-C) above the feed zone(BZ-B). The splash zone (BZ-C) is proximate to the fluid bed level (L-B)and below the freeboard zone (FB-B). In embodiments, the dense bed zone(BZ-A) corresponds to the lower portion of the dense bed within thesecond interior (201). In embodiments, the feed zone (BZ-B) is locatedabove the dense bed zone (BZ-A). In embodiments, the splash zone (BZ-C)may be located above the feed zone (BZ-B) and below the second fluid bedlevel (L-B). The embodiment shown in FIG. 13 depicts the second reactorheat exchanger (HX-B) immersed below the fluid bed level (L-B) of thesecond reactor (200).

The second reactor heat exchanger (HX-B) comprises: a second reactorheat transfer medium inlet (212) configured to receive a heat transfermedium (210) at a second reactor inlet temperature (T1); and a secondreactor heat transfer medium outlet (216) configured to output the heattransfer medium (210), at a higher, second reactor outlet temperature(T2).

A second reactor heat transfer medium supply valve (VB0), configured toaccept a signal (XB0) from a controller (CB0) is installed upstream ofthe second reactor heat transfer medium inlet (212) to control theamount of heat transfer medium (210) supplied to the second reactor heatexchanger (HX-B). The heat transfer medium (210) is supplied via thesecond reactor heat transfer medium input (3B-IN2) or third reactor heattransfer medium output (3C-OUT2). As depicted in FIG. 3, a portion ofthe third reactor heat transfer medium (310) is used as the secondreactor heat transfer medium (210). Thus, the inlet (212) of the secondreactor heat exchanger (HX-B) is fluidly in communication with theoutlet (316) of the third reactor heat exchanger (HX-C).

The upstream first reactor (100) is in fluid communication with thesecond reactor heat transfer medium outlet (216) of the second reactorheat exchanger (HX-B) and is configured to introduce at least a portionof second reactor heat transfer medium (210) into the first reactor(100) via a first reactor reactant input (3A-IN2) or a second reactorheat transfer medium output (3B-OUT2). Therefore, the upstream firstreactor (100) is also in fluid communication with the third reactor heattransfer medium outlet (316) of the third reactor heat exchanger (HX-C)and is configured to introduce at least a portion of the third reactorheat transfer medium (310) into the first reactor (100).

The second interior (201) of the second reactor (200) is in fluidcommunication with the second reactor heat transfer medium outlet (216)of the second reactor heat exchanger (HX-B) and is configured tointroduce at least a portion of second reactor heat transfer medium(210) into the second reactor (200). Therefore, the second interior(201) of the second reactor (200) is in fluid communication with thethird reactor heat transfer medium outlet (316) of the third reactorheat exchanger (HX-C) and is configured to introduce at least a portionof the third reactor heat transfer medium (310) into the second reactor(200).

FIG. 13 further illustrates a Second Stage Product Gas GenerationControl Volume (CV-3B) and Second Stage Product Gas Generation System(3B) showing a first reactor product gas input (3B-IN1) entering as afirst solids separation device (150) as a first reactor product gasoutput (3A-OUT1). FIG. 13 further illustrates a Second Stage Product GasGeneration Control Volume (CV-3B) and Second Stage Product GasGeneration System (3B) discharging a product gas output (3B-OUT1) as acombined product gas input (3C-IN1) to the Third Stage Product GasGeneration System (3C) within the Third Stage Product Gas GenerationControl Volume (CV-3C).

The first solids separation device (150) is comprised of: a firstseparation input (152) in fluid communication with the first reactorproduct gas output (124); a first separation char output (154) in fluidcommunication with the second reactor char input (204); and a firstseparation gas output (156). The second reactor (200) is configured toaccept a char (202) through a second reactor char input (204) routed tothe second interior (201) via a dipleg (244).

A riser (236) connects the interior (201) of the second reactor (200)with the terminal portion (242) of the conduit that connects the firstreactor product gas output (124) with the first separation input (152).The riser (236) is configured to transport particulate heat transfermaterial (205) from the interior (201) of the second reactor (200) viariser connection (238) to the first separation input (152).

In embodiments, the second reactor particulate heat transfer material(205) is comprised of Geldart Group A or Group B solids in the form ofinert material or catalyst or sorbent or engineered particles. Theengineered particles may be made of alumina, zirconia, sand, olivinesand, limestone, dolomite, or catalytic materials, any of which may behollow in form, such as microballoons or microspheres. The preferredsecond reactor particulate heat transfer material (205) is Geldart GroupB alumina microballons. The second reactor particulate heat transfermaterial (205) enhances mixing, heat and mass transfer, and reactionbetween the char (202) and the reactant (206A, 206B, 206C) oroxygen-containing gas (218A, 218B, 218C) introduced to the secondreactor (200).

A riser conveying fluid (240) is preferably introduced to the riser(236) to assist in uniform flow of particulate heat transfer material(205) from the interior (201) of the second reactor (200) to the firstseparation input (152).

A solids flow regulator (245) is interposed in between the firstseparation char output (154) and the second reactor char input (204) andconfigured as a sealing apparatus to prevent backflow of particulateheat transfer material (205) from the interior (201) of the secondreactor (200). The solids flow regulator (245) is comprised of: a solidsflow regulator solids input (246) configured to receive char (202) andsolids (205) separated from the first separation char output (154) ofthe first solids separation device (150); a solids flow regulator solidsoutput (247) configured to output char (202) and solids (205) to thesecond reactor char input (204) via a dipleg (244); a solids flowregulator gas input (248) to accept a solids flow regulator gas (249).

Connection X7 in FIG. 13 shows a gas input (3B-IN4) being used as theriser conveying fluid (240) originating from a downstream Secondary GasClean-Up System (6000) as a carbon dioxide output (6-OUT2) also asdepicted in FIG. 25 and FIG. 26. In embodiments, the solids flowregulator gas (249) originates from a downstream Secondary Gas Clean-UpSystem (6000) as a carbon dioxide output (6-OUT2) and is transferredfrom connection X7 to the solids flow regulator gas input (248).

The first separation char output (154) of the first solids separationdevice (150) is configured to output char (202) and is in fluidcommunication with the second reactor (200) via a second reactor charinput (204). The first separation gas output (156) of the first solidsseparation device (150) is configured to output a char depleted firstreactor product gas (126) via a char depleted first reactor product gasconduit (128).

The second reactor (200) comprises: a second reactor char input (204) tothe second feed zone (BZ-B), said second reactor char input (204) beingin fluid communication with the first reactor product gas output (124);a second reactor dense bed zone reactant input (208A) configured tointroduce a second reactor dense bed zone reactant (206A) to the seconddense bed zone (BZ-A); a second reactor feed zone reactant input (208B)configured to introduce a second reactor feed zone reactant (206B) tothe second feed zone (BZ-B); a second reactor splash zone reactant input(208C) configured to introduce a second reactor splash zone reactant(206C) to the second splash zone (BZ-C); a second reactor dense bed zoneoxygen-containing gas input (220A) configured to introduce a secondreactor dense bed zone oxygen-containing gas (218A) to the second densebed zone (BZ-A); a second reactor feed zone oxygen-containing gas input(220B) configured to introduce a second reactor feed zoneoxygen-containing gas (218B) to the second feed zone (BZ-B); a secondreactor splash zone oxygen-containing gas input (220C) configured tointroduce a second reactor splash zone oxygen-containing gas (218C) tothe second splash zone (BZ-C); a second reactor product gas output(224); and, a second reactor heat exchanger (HX-B) in thermal contactwith the second interior (201); wherein:

the second reactor heat exchanger (HX-B) is configured to receive a heattransfer medium (210) at a second reactor inlet temperature (T1) andoutput the heat transfer medium (210), at a higher, second reactoroutlet temperature (T2), via a second reactor heat transfer mediumoutlet (216); and, the second reactor heat transfer medium outlet (216)is configured to be selectively in fluid communication with anycombination of the first reactor dense bed zone reactant input (108A),the first reactor feed zone reactant input (108B) and the first reactorsplash zone reactant input (108C); and, the second reactor heat transfermedium outlet (216) is configured to be selectively in fluidcommunication with any combination of the second reactor dense bed zonereactant input (208A), second reactor feed zone reactant input (208B)and the second reactor splash zone reactant input (208C); whereby: atleast a portion of the heat transfer medium (210) is capable of beingintroduced into any combination of: (i) the corresponding second reactor(200) dense bed zone (BZ-A), (ii) the second reactor (200) feed zone(BZ-B), and (iii) the second reactor (200) splash zone (BZ-C).

Further, FIG. 13 depicts an oxygen-containing gas (218) being introducedto the Second Stage Product Gas Generation Control Volume (CV-3B) as anoxygen-containing gas input (3B-IN3) to be made available to anycombination of: (i) the corresponding second reactor (200) dense bedzone (BZ-A), (ii) the second reactor (200) feed zone (BZ-B), (iii) thesecond reactor (200) splash zone (BZ-C).

FIG. 13 depicts the system (1001) further including: a second reactordense bed zone reactant input (208A) and second reactor dense bed zoneoxygen-containing gas input (220A) in fluid communication with a densebed zone steam/oxygen connection (BZA0). The dense bed zone steam/oxygenconnection (BZA0) is in fluid communication with the dense bed zonesteam/oxygen (BZA2) and configured to transport the dense bed zonesteam/oxygen (BZA1) to the second reactor (200) dense bed zone (BZ-A).The second reactor (200) dense bed zone steam/oxygen (BZA1) is a mixtureof the second reactor dense bed zone reactant (206A) and second reactordense bed zone oxygen-containing gas (218A).

A second reactor dense bed zone reactant valve (VB1), configured toaccept a signal (XB1) from a controller (CB1) is installed upstream ofthe input (208A) to control the amount of reactant (206A) supplied tothe second reactor (200) dense bed zone (BZ-A). A second reactor densebed zone oxygen-containing gas valve (VB2), configured to accept asignal (XB2) from a controller (CB2) is installed upstream of the input(220A) to control the amount of oxygen-containing gas (218A) supplied tothe second reactor (200) dense bed zone (BZ-A).

FIG. 13 depicts the system (1001) further including: a second reactorfeed zone reactant input (208B) and second reactor feed zoneoxygen-containing gas input (220B) in fluid communication with a feedzone steam/oxygen connection (BZB0). The feed zone steam/oxygenconnection (BZB0) is in fluid communication with the feed zonesteam/oxygen input (BZB2) and configured to transport the feed zonesteam/oxygen (BZB1) to the second reactor (200) feed zone (BZ-B). Thesecond reactor (200) feed zone steam/oxygen (BZB1) is a mixture of thesecond reactor feed zone reactant (206B) and second reactor feed zoneoxygen-containing gas (218B).

A second reactor feed zone reactant valve (VB3), configured to accept asignal (XB3) from a controller (CB3) is installed upstream of the input(208B) to control the amount of reactant (206B) supplied to the secondreactor (200) feed zone (BZ-B). A second reactor feed zoneoxygen-containing gas valve (VB4), configured to accept a signal (XB4)from a controller (CB4) is installed upstream of the input (220B) tocontrol the amount of oxygen-containing gas (218B) supplied to thesecond reactor (200) feed zone (BZ-B).

FIG. 13 depicts the system (1001) further including: a second reactorsplash zone reactant input (208C) and second reactor splash zoneoxygen-containing gas input (220C) in fluid communication with a splashzone steam/oxygen connection (BZC0). The splash zone steam/oxygenconnection (BZC0) is in fluid communication with the splash zonesteam/oxygen input (BZC2) and configured to transport the splash zonesteam/oxygen (BZC1) to the second reactor (200) splash zone (BZ-C). Thesecond reactor (200) splash zone steam/oxygen (BZC1) is a mixture of thesecond reactor splash zone reactant (206C) and second reactor splashzone oxygen-containing gas (218C).

A second reactor splash zone reactant valve (VB5), configured to accepta signal (XB5) from a controller (CB5) is installed upstream of theinput (208C) to control the amount of reactant (206C) supplied to thesecond reactor (200) splash zone (BZ-C). A second reactor splash zoneoxygen-containing gas valve (VB6), configured to accept a signal (XB6)from a controller (CB6) is installed upstream of the input (220C) tocontrol the amount of oxygen-containing gas (218C) supplied to thesecond reactor (100) splash zone (BZ-C).

An internal cyclone (225) is shown in the freeboard zone (FB-B) of thesecond reactor (200). A restriction orifice differential pressure sensor(DP-AB) is shown to measure the pressure drop across the restrictionorifice (RO-B). A fuel input (264) is shown on the second reactor (200)and is configured to introduce a source of fuel (262) to the interior(201) of the second reactor (200). In embodiments, the fuel (262) may beprovided to the second reactor (200) via a fuel input (3B-IN5)transferred from a fuel output (4-OUT2) from a downstream Primary GasClean Up System (4000) as depicted in FIG. 25 and FIG. 26. The fueloutput (4-OUT2) may include VOC, SVOC, hydrocarbons such as solvents,Fischer Tropsch Products such as naphtha, or carbonaceous materials inthe liquid, solid, or slurry form including coal or char.

A second reactor hydrocarbon valve (VB7) is positioned upstream of thefuel input (264) on the second reactor (200), and is configured toaccept a signal (XB7) from a controller (CB7) to control the amount offuel (262) supplied to the second reactor (200).

Char (202) is introduced to the interior (201) of the second reactor(200) for intimate contact with the particulate heat transfer material(205), reactants (206A, 206B, 206C), and oxygen-containing gas (218,218A, 218B, 218C) to produce a second reactor product gas (222) that isdischarged via a second reactor product gas output (224).

The second solids separation device (250) is configured to accept asecond reactor product gas (222) and output a solids depleted secondreactor product gas (226) via a solids depleted second reactor productgas conduit (228). The second solids separation device (250) has asecond separation input (252) in fluid communication with the secondreactor product gas output (224). The second solids separation device(250) has a second separation solids output (254) in fluid communicationwith a solids transfer conduit (234) and is configured to output secondreactor separated solids (232) such as char or ash. The secondseparation gas output (256) of the solids separation device (250) is influid communication with the char depleted first reactor product gasconduit (128) or the combined reactor product gas conduit (230).

FIG. 13 refers to a second reactor feed zone cross-sectional view(XBZ-B) that will be elaborated upon in FIGS. 14, 15, 16, and 17. FIG.13 also refers to a second reactor splash zone cross-sectional view(XBZ-C) that will be elaborated upon in FIG. 18.

FIG. 14:

FIG. 14 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 13, including:one first solids separation device (150); four second reactor charinputs (204A, 204B, 204C, 204D); four feed zone steam/oxygen inputs(BZB2, BZB3, BZB4, BZB5); and, where the combined reactor product gasconduit (230) is configured to blend the first reactor product gas (126)with the second reactor product gas (226).

FIG. 14 depicts four separate second reactor char inputs (204A, 204B,204C, 204D) for transferring four separate streams of char (202A, 202B,202C, 202D) to the feed zone (BZ-B) of the second reactor (200). Thefour separate streams of char (202A, 202B, 202C, 202D) may be reactedwith the four feed zone steam/oxygen inputs (BZB2, BZB3, BZB4, BZB5) togenerate a second reactor product gas (222). The second reactor productgas (222) may in turn be routed to the inlet (252) of a second solidsseparation device (250). The second solids separation device (250) isconfigured to separate solids (232) from the product gas (222) to resultin a solids depleted second reactor product gas (226). The solidsdepleted second reactor product gas (226) is shown to be routed to thecombined reactor product gas conduit (230) via a conduit (228). Thefirst reactor product gas (126) may be combined with the second reactorproduct gas (226) in a combined reactor product gas conduit (230).

FIG. 15:

FIG. 15 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 13 where thefirst reactor product gas (126) is not combined with the second reactorproduct gas (226).

FIG. 16:

FIG. 16 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 13, including:two first solids separation devices (150A1, 150A2); two solids flowregulators (245A, 245B); four second reactor char inputs (204A, 204B,204C, 204D); four feed zone steam/oxygen inputs (BZB2, BZB3, BZB4,BZB5); and the combined reactor product gas conduit (230), configured toblend the first reactor product gas (126A1, 126A2) with the secondreactor product gas (226).

FIG. 16 elaborates upon the embodiment where each of two first solidsseparation devices (150A1, 150A2) accept a portion of the first reactorproduct gas (122). One first solids separation device (150A) accepts aportion of the first reactor product gas (122A1) via a first separationinput (152A1). Another first solids separation device (150B) acceptsanother portion of the first reactor product gas (122A2) via a firstseparation input (152A2). Each first solids separation device has adipleg (244A, 244B) that is connected to a respective solids flowregulator (245A, 245B).

One first solids separation device (150A1) accepts a portion of thefirst reactor product gas (122A1) removes char (202A, 202D) therefromfor transfer to the second reactor (200) and outputs a char depletedfirst reactor product gas (126A1) via a char depleted first reactorproduct gas conduit (128A1). Another first solids separation device(150A2) accepts a portion of the first reactor product gas (122A2)removes char (202B, 202C) therefrom for transfer to the second reactor(200) and outputs a char depleted first reactor product gas (126A2) viaa char depleted first reactor product gas conduit (128A2). Each chardepleted first reactor product gas conduit (128A1, 128A2) may becombined into one common conduit (128).

The first separation char output (154A1) on one first solids separationdevice (150A1) is in fluid communication with the first solids flowregulator solids input (246A) of the first solids flow regulator (245A)via a dipleg (244A). The first separation char output (154A2) on theother first solids separation device (150A2) is in fluid communicationwith the second solids flow regulator solids input (246B) of the secondsolids flow regulator (245B) via a dipleg (244B).

One solids slow regulator (245A) has a first solids flow regulatorsolids output (247A) and a second solids flow regulator solids output(247B). The first solids flow regulator solids output (247A) is in fluidcommunication with the second reactor fourth char input (204D) and isconfigured to transfer char (202D) to the second reactor (200). Thesecond solids flow regulator solids output (247B) is in fluidcommunication with the second reactor first char input (204A) and isconfigured to transfer char (202A) to the second reactor (200).

Another solids slow regulator (245B) has a third solids flow regulatorsolids output (247C) and a fourth solids flow regulator solids output(247D). The third solids flow regulator solids output (247C) is in fluidcommunication with the second reactor third char input (204C) and isconfigured to transfer char (202C) to the second reactor (200). Thefourth solids flow regulator solids output (247D) is in fluidcommunication with the second reactor second char input (204B) and isconfigured to transfer char (202B) to the second reactor (200).

FIG. 17:

FIG. 17 shows a non-limiting embodiment of a second reactor feed zonecross-sectional view (XBZ-B) of the embodiment in FIG. 16 where thefirst reactor product gas (126A1, 126A2) is not combined with the secondreactor product gas (226).

FIG. 18:

FIG. 18 shows a non-limiting embodiment of a second reactor splash zonecross-sectional view (XBZ-C) of the embodiment in FIG. 13, includingfour splash zone steam/oxygen inputs (BZC2, BZC3, BZC4, BZC5) configuredto accept a source of splash zone steam/oxygen (BZC1).

FIG. 19:

FIG. 19 elaborates upon the non-limiting embodiment of FIG. 7 furtherincluding two particulate classification vessels (A1A, A1B) that areconfigured to accept a bed material and inert feedstock contaminantmixture (A4A, A4AA), and a classifier gas (A16, A16A) and to classify orclean and recycle the bed material portion back to the first interior(101) of the first reactor (100) while removing the inert feedstockcontaminant portion from the system as a solids output (3A-OUT3).

The product gas generation and particulate classification system (1002)shown in FIG. 19 depicts a Product Gas Generation System (3A) configuredto produce both a product gas (122) and classified inert feedstockcontaminants (A19, A19A) from a carbonaceous material (102). The system(1002) comprises a first reactor (100) having a first interior (101) andcomprising: a first reactor carbonaceous material input (104) to thefirst interior (101); a first reactor reactant input (108A, 108B, 108C)to the first interior (101); a first reactor product gas output (124)from the first interior (101); a classified recycled bed material input(A27, A27A) to the first interior (101); and, a bed material and inertfeedstock contaminant mixture output (A2A, A2AA) from the first interior(101).

The system (1002) further comprises two particulate classificationvessels (A1A, A1B) each having a classifier interior (INA, INB) andcomprising: a bed material and inert feedstock contaminant mixture input(A5A, A5AA), a classifier gas input (A6A, A6AA), a classified recycledbed material output (A7A, A7AA), a classifier depressurization gasoutput (A8A, A8AA), and a classifier inert feedstock contaminant output(A9A, A9AA).

The system (1002) shown in FIG. 19 depicts one first reactor (100)equipped with two particulate classification vessels (A1A, A1B). Eachparticulate classification vessel (A1A, A1B) is equipped with a bedmaterial and inert feedstock contaminant mixture input (A5A, A5AA) influid communication with the first interior (101) of the first reactor(100) through a bed material and inert feedstock contaminant mixtureoutput (A2A, A2AA) and a bed material and inert feedstock contaminantmixture transfer conduit (A3A,A3AA). Each bed material and inertfeedstock contaminant mixture input (A5A, A5AA) is configured tointroduce a bed material and inert feedstock contaminant mixture (A4A,A4AA) to the interior (INA, INB) via a bed material and inert feedstockcontaminant mixture transfer conduit (A3A, A3AA).

The bed material and inert feedstock contaminant mixture (A4A, A4AA) iscomprised of a bed material portion and an inert feedstock contaminantportion. The bed material portion is synonymous with the first reactorparticulate heat transfer material (105).

MSW and/or RDF are carbonaceous materials that contain inert feedstockcontaminants in the form of Geldart Group D particles comprising wholeunits and/or fragments of one or more from the group consisting of allenwrenches, ball bearings, batteries, bolts, bottle caps, broaches,bushings, buttons, cable, cement, chains, clips, coins, computer harddrive shreds, door hinges, door knobs, drill bits, drill bushings,drywall anchors, electrical components, electrical plugs, eye bolts,fabric snaps, fasteners, fish hooks, flash drives, fuses, gears, glass,gravel, grommets, hose clamps, hose fittings, jewelry, key chains, keystock, lathe blades, light bulb bases, magnets, metal audio-visualcomponents, metal brackets, metal shards, metal surgical supplies,mirror shreds, nails, needles, nuts, pins, pipe fittings, pushpins,razor blades, reamers, retaining rings, rivets, rocks, rods, routerbits, saw blades, screws, sockets, springs, sprockets, staples, studs,syringes, USB connectors, washers, wire, wire connectors, and zippers.Thus when MSW and/or RDF are transferred to the first reactor (100),inert feedstock contaminants contained therein, are also unavoidablytransferred to the first reactor (100) as well.

The inert feedstock contaminant portion of the MSW carbonaceous material(102) of FIG. 19 is that which cannot be converted into a product gas(122) and as a result, accumulates within the interior (101) of thefirst reactor (100). It is therefore desirable to be able to removeGeldart Group D inert feedstock contaminant solids which may accumulatewithin the first reactor (100). Thus it is therefore desirable to beable to clean bed material by classification or via the removal ofGeldart Group D inert feedstock contaminant solids therefrom to permitcontinuous and uninterrupted operation within the first reactor (100).

The accumulation of Geldart Group D inert feedstock contaminant solidswithin the first reactor (100) inhibits continuous operation of thefirst reactor (100) and may cause defluidization within the firstreactor (100). Defluidization of the first reactor (100) may be causedby unpredictable and unavoidable buildup of larger Geldart particles, incomparison to the mean bed particle characteristic, introduced to theinterior (101). For example, FIG. 19 depicts an interior (101) comprisedof a fluidized bed of a mean bed particle characteristic of GeldartGroup B solids which may become defluidized by buildup or accumulationof comparatively larger, coarser and/or heavier Geldart Group D solidsthat are introduced to the fluidized bed with the carbonaceous material(102).

A mixture transfer valve (V9, V9A, V9AA) is interposed in each mixturetransfer conduit (A3A, A3AA) in between the first reactor (100) and eachparticulate classification vessel (A1A, A1B) to start and stop flow ofthe contents transferred therein, and to isolate the particulateclassification vessel (A1A, A1B) from the first reactor (100).

Each particulate classification vessel (A1A, A1B) is equipped with aclassifier gas input (A6A, A6AA) configured to introduce a classifiergas (A16, A16A) to each interior (IN1, INB). The classifier gas input(A6A, A6AA) may be in fluid communication with the carbon dioxide output(6-OUT2) of a downstream Secondary Gas Clean-Up System (6000) as seen inFIGS. 25 and 26. The classifier gas (A16, A16A) is preferably carbondioxide. However, the classifier gas (A16, A16A) may be any gas asdeemed appropriate, such as nitrogen, product gas, air, hydrocarbons,refinery off-gases, or the like.

A classification gas transfer valve (V10, V10A, V10AA) is configured toregulate classifier gas (A16, A16A) flow through the classifier gasinput (A6A, A6AA) to the interior (INA, INB) of the particulateclassification vessel (A1A, A1B). Each particulate classification vessel(A1A, A1B) is equipped with a classified recycled bed material output(A7A, A7AA) in fluid communication with the interior (101) of the firstreactor (100) via a classified recycled bed material input (A27, A27A)and a classifier riser (A17, A17A).

The classified recycled bed material input (A27, A27A) is preferablypositioned at or above the fluid bed level (L-A) of the first reactor(100) so as to let the recycled bed material or particulate heattransfer material (105) to be recycled back to the interior (101) of thefirst reactor (100) in an unimpeded manner.

A bed material riser recycle transfer valve (V11, V11A, V11AA) isinterposed in each classifier riser (A17, A17A) in between the firstreactor (100) and each particulate classification vessel (A1A, A1B) tostart and stop flow of the contents transferred therein, and to isolatethe particulate classification vessel (A1A, A1B) from the first reactor(100).

Each particulate classification vessel (A1A, A1B) is equipped with aclassifier inert feedstock contaminant output (A9A, A9AA) configured toremove classified inert feedstock contaminants (A19, A19A) from theinterior (INA, INB).

An inert feedstock contaminant drain valve (V13, V13A, V13AA) isconfigured to start and stop flow of classified inert feedstockcontaminants (A19, A19A) transferring through the classifier inertfeedstock contaminant output (A9A, A9AA).

Each particulate classification vessel (A1A, A1B) may also be equippedwith a classifier depressurization gas output (A8A, A8AA) configured toevacuate classifier depressurization gas (A18, A18A) from the interior(INA, INB) thus reducing the pressure contained therein.

A depressurization vent valve (V12, V12A, V12AA) is configured to startand stop flow of classifier depressurization gas (A18, A18A) transferredthrough the classifier depressurization gas output (A8A, A8AA).

The classified recycled bed material output (A7A, A7AA) is configured tooutput a classified recycled bed material (A37, A37A) to the interior(101) of the first reactor (100). In embodiments, the classifier riser(A17, A17A) conveys the classified recycled bed material (A37, A37A) tothe interior (101) of the first reactor (100) in a suspension of gas(A16, A16A) and conveyed in a dilute-phase flow regime.

A carbonaceous material input (3A-IN1) is introduced to the as firstreactor carbonaceous material input (104) and is configured to provide acarbonaceous material (102) to the feed zone (AZ-B) of the first reactor(100). A carbonaceous material (102) is introduced to the interior (101)of the first reactor (100) for intimate contact with the heatedparticulate heat transfer material (105), reactants (106, 106A, 106B,106C) and oxygen-containing gas (118, 118 a, 118B, 118C) containedwithin the interior (101) to produce a first reactor product gas (122)that is discharged from the interior (101) of the first reactor (100)via a first reactor product gas output (124).

FIG. 19 is to be used in conjunction with FIG. 20 which depicts a valvesequencing diagram that describes the method of operating the sequenceof the product gas generation and particulate classification system(1002) embodiment shown in FIG. 19.

FIG. 19 shows one embodiment of the product gas generation andparticulate classification system (1002) equipped with a variety ofsensors, valves, assets and controllers which are all configured tomethodically and systematically manipulate the operation of theparticulate classification vessel (A1A, A1B) to accept a variety ofinputs and discharge a variety of outputs to and from the first reactor(100).

The particulate classification vessel (A1A, A1B) is configured to acceptthe bed material and inert feedstock contaminant mixture (A4A, A4AA)transferred from the interior (101) of the first reactor (100). Inembodiments, the bed material and inert feedstock contaminant mixture(A4A, A4AA) are conveyed in a dense phase flow regime through themixture transfer conduit (A3A, A3AA) into the classifier interior(INA,INB). The bed material and inert feedstock contaminant mixture(A4A, A4AA) is comprised of a bed material portion and an inertfeedstock contaminant portion. The bed material and inert feedstockcontaminant mixture (A4A, A4AA) is transferred to the classifierinterior (INA, INB) via a mixture transfer conduit (A3A, A3AA) and flowis regulated through modulation or actuation of an associated mixturetransfer valve (V9A, V9AA).

The embodiments shown in FIG. 7 and FIG. 19 show the first reactor (100)having particulate heat transfer material (105) with a mean bed particlecharacteristic including Geldart Group B solids. Therefore the bedmaterial portion of the mixture (A4A, A4AA) is comprised of GeldartGroup B solids and the inert feedstock contaminant portion is comprisedof Geldart Group D solids. The embodiment of FIG. 19 shows theclassification vessel (A1A, A1B) configured to accept a classifier gas(A16, A16A), such as carbon dioxide, the supply of which is regulatedthrough modulation or actuation of a classification gas transfer valve(V10A, V10AA).

In response to accepting the gas (A16, A16A), the classification vessel(A1A, A1B) is configured to output: (1) a bed material portion to bereturned to the first reactor (100); and, (2) an inert feedstockcontaminant portion to be discharged from the classifier vessel (A1A,A1B). As a result, the bed material and inert feedstock contaminantmixture (A4A, A4AA) is cleaned to separate the bed material portion(Geldart Group B solids) from the inert feedstock contaminant portion(Geldart Group D solids). The cleaned and separated bed material portion(Geldart Group B solids) is then available to be used again in the firstreactor (100) in a thermochemical process to generate a product gas.

The system in FIG. 19 displays a first reactor (100) configured toaccept a carbonaceous material (102), such as MSW containing inertfeedstock contaminants. The system in FIG. 19 also displays a firstreactor (100) configured to accept a first reactor reactant input(3A-IN2) or the second reactor heat transfer medium output (3B-OUT2),such as steam, from the third reactor heat exchanger (HX-C) (not shown).The system in FIG. 19 also displays a first reactor (100) configured toaccept an oxygen-containing gas (118) through an input (3A-IN3).

FIG. 25 and FIG. 26 display a Refinery Superstructure System (RSS)equipped with a Secondary Gas Clean-Up System (6000) configured toremove carbon dioxide from product gas. The Secondary Gas Clean-UpSystem (6000) has a carbon dioxide laden product gas input (6-IN1) and acarbon dioxide depleted product gas output (6-OUT1). Membrane basedcarbon dioxide removal systems and processes are preferred to removecarbon dioxide from product gas, however other alternate systems andmethods may be utilized to remove carbon dioxide, not limited toadsorption or absorption based carbon dioxide removal systems andprocesses.

FIG. 25 and FIG. 26 display the Secondary Gas Clean-Up System (6000)discharging a carbon dioxide output (6-OUT2) to both the (1) First StageProduct Gas Generation System (3A), for use as a classifier gas (A16,A16A), and to the (2) the Feedstock Delivery System (2000) to becombined with a carbonaceous material (500). Thus FIG. 19 displays theproduct gas generation and particulate classification system (1002) inthe context of a Refinery Superstructure System (RSS) as depicted inFIG. 25 and FIG. 26 and displays the introduction of the combinedcarbonaceous material and carbon dioxide into a first reactor via acarbonaceous material input (3A-IN1).

Thus FIG. 19 depicts the system (1002) configured to react the MSWcarbonaceous material with steam, carbon dioxide, and anoxygen-containing gas in a thermochemical process to generate a firstreactor product gas containing char. For example, in embodiments, thefirst reactor (100) in FIG. 19 operates under a combination of steamreforming, water-gas shift, dry reforming, and partial oxidationthermochemical processes. FIG. 19 also shows combustion taking placewithin the first reactor first heat exchangers (HX-A1, HX-A2, HX-A3,HX-A4) to indirectly heat the first reactor particulate heat transfermaterial (105) contained within the first reactor (100). The firstreactor particulate heat transfer material (105) essentially is a bedmaterial and inert feedstock contaminant mixture due to the introductionof MSW introduced to the reactor that contains inert feedstockcontaminants that build up within the interior (101) of the firstreactor (100).

The product gas shown generated in FIG. 19 contains carbon dioxide,which is then later separated out in the Secondary Gas Clean-Up System(6000) to allow the carbon dioxide to be recycled back to the (1)Feedstock Delivery System (2000) to be combined with a carbonaceousmaterial for transfer to the first reactor (100), and the (2) FirstStage Product Gas Generation System (3A) for use as a classifier gas(A16, A16A) to clean the bed material. Thus the first particulate heattransfer material may be cleaned with a gas, or a portion of the productgas generated in the first reactor (100), such as for example, thecarbon dioxide portion of the product gas generated in the first reactorthat is recycled from a downstream Secondary Gas Clean-Up System (6000).

The embodiment of FIG. 19 shows the bed material portion comprised ofGeldart Group A or B solids free of inert contaminants, transferred andregulated through actuation or modulation of a bed material riserrecycle transfer valve (V11A, V11AA) that is positioned on a classifierriser (A17,A17A).

The embodiment of FIG. 19 also shows the classification vessel (A1A,A1B) configured to transfer Geldart Group D solids free of Geldart GroupA or B solids as an inert feedstock contaminant portion from theclassifier vessel (A1A, A1B) for removal from the via an inert feedstockcontaminant drain valve (V13A, V13AA) positioned on the classifier inertfeedstock contaminant output (A9A, A9AA)

FIG. 19 also shows a mass sensor (WT-1) positioned on the particulateclassification vessel (A1B) to measure the mass of the bed material andinert feedstock contaminant mixture (A4AA) entering the particulateclassification vessel (A1B). The mass sensor (WT-1) is also configuredto measure the mass lost from the particulate classification vessel(A1B) due to the classified recycled bed material (A37A) transported tothe first reactor (100) via the classifier riser (A17A) using theclassifier gas (A16A) as the transport motive.

A depressurization vent valve (V12A, V12AA) may optionally be utilizedto evacuate residual pressured gas from the contents of theclassification vessel (A1A, A1B) to prevent erosion and solids abrasionof solids passing through the inert feedstock contaminant drain valve(V13A, V13AA).

In embodiments, FIG. 19 depicts a municipal solid waste (MSW) energyrecovery system for converting MSW containing inert feedstockcontaminants, into a product gas (122), the system comprising: (a) afirst reactor (100) comprising: a first reactor interior (101) suitablefor accommodating a bed material and endothermically reacting MSW in thepresence of steam to produce product gas; a first reactor carbonaceousmaterial input (104) for introducing MSW into the first reactor interior(101); a first reactor reactant input (108A, 108B, 108C) for introducingsteam into the first interior (101); a first reactor product gas output(124) through which product gas is removed; a classified recycled bedmaterial input (A27, A27A) in fluid communication with an upper portionof the first reactor interior (101); a particulate output (A2A, A2AA)connected to a lower portion of the first reactor interior, and throughwhich a mixture (A4A, A4AA) of bed material and unreacted inertfeedstock contaminants selectively exits the first reactor interior; and(b) a plurality of particulate classification vessels (A1A, A1B) influid communication with the first reactor interior (101), each vesselcomprising: (i) a mixture input (A5A, A5AA) connected to the particulateoutput (A2A, A2AA), for receiving said mixture from the first reactorinterior (101); (ii) a classifier gas input (A6A, A6AA) connected to asource of classifier gas (A16, A16A), for receiving classifier gas topromote separation of said bed material from said unreacted inertfeedstock contaminants within said vessel; (iii) a bed material output(A7A, A7AA) connected to the classified recycled bed material input(A27, A27A) of the first reactor interior (101) via a classifier riserconduit (A17, A17A), for returning bed material separated from saidmixture to the first reactor interior; and (iv) a contaminant output(A9A, A9AA) for removing unreacted inert feedstock contaminants (A19,A19A) which have been separated from said mixture, within the vessel.

In embodiments, FIG. 19 discloses a mixture transfer valve (V9A, V9AA)positioned between the particulate output (A2A, A2AA) and the mixtureinput (A5A, A5AA), to selectively control transfer of said mixture fromthe first reactor to the vessel; a classification gas transfer valve(V10A, V10AA) positioned between the source of classifier gas (A16,A16A) and the classifier gas input (A6A, A6AA), to selectively providesaid classifier gas to the vessel; a bed material riser recycle transfervalve (V11A, V11AA) positioned between the bed material output (A7A,A7AA) and the classified recycled bed material input (A27, A27A), toselectively return bed material separated from said mixture, to thefirst reactor interior; and an inert feedstock contaminant drain valve(V13A, V13AA) configured to selectively remove unreacted inert feedstockcontaminants (A19, A19A) which have been separated from said mixture. Inembodiments, each vessel further comprises a classifier depressurizationgas output (A8A, A8AA) and a depressurization vent valve (V12A, V12AA)connected to the classifier depressurization gas output (A8A, A8AA) toselectively vent the vessel.

In embodiments, FIG. 19 depicts a master controller configured tooperate the system in any one of a plurality of states disclosed in FIG.20, including: a first state in which all of said valves are closed; asecond state in which the mixture transfer valve (V9A, V9AA) is open andthe remainder of said valves are closed, to allow said mixture to enterthe vessel; a third state in which the classification gas transfer valve(V10A, V10AA) and the bed material riser recycle transfer valve (V11A,V11AA) are open and the remainder of said valves are closed, to promoteseparation of said bed material from said mixture and recycling ofseparated bed material back into the first reactor; a fourth state inwhich the depressurization vent valve (V12A, V12AA) is open and theremainder of said valves are closed, to allow the vessel to vent; and afifth state in which the inert feedstock contaminant drain valve (V13A,V13AA) is open and the remainder of said valves are closed, to removeunreacted inert feedstock contaminants from the vessel. In embodiments,the classifier gas may be carbon dioxide. In embodiments, the productgas (122) generated comprises carbon dioxide and a first portion of thecarbon dioxide in the product gas (122) may be introduced into thevessel as the classifier gas.

In embodiments, FIG. 19 further discloses that the inert feedstockcontaminants comprise a plurality of different Geldart Group D solidshaving a size greater than 1000 microns; and the Geldart Group D solidsmay comprise whole units and/or fragments of one or more of the groupconsisting of allen wrenches, ball bearings, batteries, bolts, bottlecaps, broaches, bushings, buttons, cable, cement, chains, clips, coins,computer hard drive shreds, door hinges, door knobs, drill bits, drillbushings, drywall anchors, electrical components, electrical plugs, eyebolts, fabric snaps, fasteners, fish hooks, flash drives, fuses, gears,glass, gravel, grommets, hose clamps, hose fittings, jewelry, keychains, key stock, lathe blades, light bulb bases, magnets, metalaudio-visual components, metal brackets, metal shards, metal surgicalsupplies, mirror shreds, nails, needles, nuts, pins, pipe fittings,pushpins, razor blades, reamers, retaining rings, rivets, rocks, rods,router bits, saw blades, screws, sockets, springs, sprockets, staples,studs, syringes, USB connectors, washers, wire, wire connectors, andzippers.

In embodiments, the bed material separated from the mixture and returnedto the first reactor interior may comprise Geldart Group A solidsranging in size from about 30 microns to about 99.99 microns. TheseGeldart Group A solids may comprise one or more of the group consistingof inert material, catalyst, sorbent, engineered particles andcombinations thereof. The engineered particles comprise one or more ofthe group consisting of alumina, zirconia, sand, olivine sand,limestone, dolomite, catalytic materials, microballoons, microspheres,and combinations thereof.

In embodiments, the bed material separated from said mixture andreturned to the first reactor interior may comprise Geldart Group Bsolids ranging in size from about 100 to about 999.99 microns. ThereGeldart Group B solids may be from one or more of group consisting ofinert material, catalyst, sorbent, and engineered particles. Theseengineered particles may comprise one or more of the group consisting ofalumina, zirconia, sand, olivine sand, limestone, dolomite, catalyticmaterials, microballoons, microspheres, and combinations thereof.

In embodiments, the first reactor is operated at a temperature between320° C. and about 900° C. to endothermically react the MSW in thepresence of steam to produce product gas. In embodiments, the firstreactor operates at any combination or permutation of thermochemicalprocesses or reactions identified above.

FIG. 20:

FIG. 20 depicts the Classification Valve States for Automated ControllerOperation of a typical particulate classification procedure. FIG. 20 isto be used in conjunction with FIG. 19 and depicts a listing of valvestates that may be used in a variety of methods to operate valvesassociated with the particulate classification vessels (A1A, A1B). FIG.20 identifies five separate discrete valve states of which any number ofstates can be selected to result in a sequence of steps for theclassification of bed material and recovery of inert feedstockcontaminants to prevent defluidization within the first reactor (100).

In embodiments, methods may be implemented for operating the product gasgeneration and classification system depicted in FIG. 19 by using thediscrete states listed in FIG. 20 to realize a sequence of steps. FIG.19 depicts a master controller, such as a control computer (COMP) thatis configured to communicate and cooperate with controllers and valvesassociated with the particulate classification vessels (A1A, A1B). Themaster control computer (COMP) may be configured to operate the systemusing any combinations and permutations of states listed in FIG. 20 orFIG. 22.

It is contemplated that in some embodiments, sequence steps of aclassification method may be chosen from any number of states listed inFIG. 20. In embodiments, sequence steps of a classification method maybe chosen from a combination of state 1, state 2, state 3, state 4,and/or state 5, and may incorporate methods or techniques describedherein and to be implemented as program instructions and data capable ofbeing stored or conveyed via a master controller. In embodiments, theclassification sequence may have only five steps which entail each ofthose listed in FIG. 20, wherein: step 1 is state 1; step 2 is state 2;step 3 is state 3; step 4 is state 4; and, step 5 is state 5. This maybe typical if a carbonaceous material comprising MSW is fed into thefirst reactor that has a relatively greater than average amount of inertfeedstock contaminants, where states 1 through 3 are not repeatedbecause a sufficient quantity of inert feedstock contaminants issufficiently present within the classifier prior to proceeding withstate 4 and state 5 to vent and drain the classifier, respectively.

In embodiments, state 1, state 2, and state 3 may be repeated at leastonce prior to implementing state 4 and state 5. For example, theclassification sequence may have eight steps, wherein states 1 through 3are repeated once prior to proceeding with state 4 and state 5, wherein:step 1 is state 1; step 2 is state 2; step 3 is state 3; step 4 is state1; and step 5 is state 2; step 6 is state 3; step 7 is state 4; and,step 8 is state 5. Thus, a classification sequence may entail amultitude of different combinations and permutations of sequence stepsgiven the operator or user defined states to be repeated. For example,from a practical perspective, if a carbonaceous material comprising MSWis fed into the first reactor that has a relatively minimal amount ofinert feedstock contaminants, states 1 through 3 may be repeated atleast once, or several times, to ensure that a sufficient quantity ofinert feedstock contaminants is present within the classifier vesselprior to proceeding with states 4 and state 5 to vent and drain theclassifier, respectively.

Nonetheless, any combination or permutation of classifier method statesand steps may be selected by a user or operator to realize the goal ofcleaning the first particulate heat transfer material with a gas, suchas carbon dioxide recycled from a downstream Secondary Gas Clean-UpSystem (6000), in a systematic, logical, and directed manner. Theobjective of the classifier (A1A) is to achieve 99% separation of themed material portion from the inert feedstock contaminant portion in theclassification state 3.

Disclosed methods or techniques may include the execution andimplementation of states associated with the Automated ControllerOperated Classification Valve Sequence Matrix as depicted in FIG. 20.Embodiments of the sequencing methods including steps and states may beimplemented by program instructions entered into the master controlcomputer (COMP) by a user or operator via an input/output interface(I/O) as disclosed in FIG. 19. Program and sequencing instructions maybe executed to perform a particular computational functions such asautomated operation of the valves associated with the product gasgeneration and classification system as depicted in FIG. 19.

FIG. 19 depicts one exemplary embodiment of a master control computer(COMP) including a processor (PROC) coupled to a system memory (MEM) viaan input/output interface (I/O). The processor (PROC) may be anysuitable processor capable of executing instructions. System memory(MEM) may be configured to store instructions and data accessible byprocessor (PROC). In various embodiments, system memory (MEM) may beimplemented using any suitable memory technology. In the illustratedembodiment, program instructions and data implementing desiredfunctions, are shown stored within system memory (MEM) as code (CODE).In embodiments, the I/O interface (I/O) may be configured to coordinateI/O traffic between processor (PROC), and system memory (MEM). In someembodiments, the I/O interface (I/O) is configured for a user oroperator to input necessary sequencing protocol into the master controlcomputer (COMP) for process execution, including sequence timing,repetition of a given number of states to realize a desired sequence ofsteps and/or states. In embodiments, the mass sensor signal (XWT1)positioned on the classifier vessel may be an input value to be enteredinto the master control computer (COMP) by the I/O interface (I/O).

Thus, the system is fully flexible to be tuned, configured, an optimizedto provide an environment for scheduling the appropriate processparameters by programmatically controlling the opening and closing ofvalves at specific time intervals. In embodiments, a user or operatormay define cycle times, step numbers, and states which may be programmedinto the master control computer (COMP) by an operator accessibleinput/output interface (I/O). In embodiments, the signal from the masssensor signal (XWT1) may be incorporated into the sequencing protocol todetermine when the classification vessel is full or empty. Inembodiments, the signal from the mass sensor signal (XWT1) is used todetermine when to switch from classification state 3 to vent state 4 toavoid clogging of the classification vessel, or to prevent processupsets, and to facilitate process optimization.

The following describes various further embodiments of the systems andmethods discussed above, and presents exemplary techniques and usesillustrating variations. Thus, the master control computer (COMP) mayimplement automation of the following controllers and their respectivevalves: mixture transfer valve controller (C9A,C9AA); classification gastransfer valve controller (C10A,C10AA); bed material riser recycletransfer valve controller (C11A,C11AA); depressurization vent valvecontroller (C12A,C12AA); and, inert feedstock contaminant drain valvecontroller (C13A,C13AA).

Controllers are shown only on the first of two shown particulateclassification vessels (A1A) for simplicity in FIG. 19. However, it isto be noted that the each valve depicted in FIG. 19 has an associatedcontroller that acts in communication with the master control computer(COMP).

FIG. 21:

FIG. 21 elaborates upon the non-limiting embodiment of FIG. 7 and FIG.19 including another embodiment of a particulate classification vessel(A1A) including gas distributor valve (V91) that separates theclassifier interior (INA) into a classifier zone (INA1) and a gasdistribution zone (INA2) and where the classifier (A1A) is configured toaccept a bed material, inert feedstock contaminant mixture (A4A), and aclassifier gas (A16) and to clean and recycle the bed material portionback to the first interior (101) of the first reactor (100) whileremoving the inert feedstock contaminant portion from the system as asolids output (3A-OUT3). Although only one particulate classificationvessel (A1A) is shown in FIG. 21 for simplicity, it is to be understoodthat two particulate classification vessels (A1A, A1B) will almostcertainly always be used. Therefore, FIG. 19 can be used to illustratethe embodiment where two particulate classification vessels (A1A, A1B)are integrated with the operation of one first reactor (100).

FIG. 21 differs from FIG. 7 and FIG. 19 in that the first reactoroxygen-containing gas (118) and reactant (106) enter the first reactor(100) through separate inputs (120 and 108, respectively) and are thenmixed prior to being distributed to the dense bed zone (AZ-A) through adistributor (145) located in the lower region of the interior (101). Thedistributor may be any suitable type to substantially, evenly distributethe mixture of oxygen-containing gas (108) and steam reactant (106)throughout the cross-sectional area of the interior (101) and dense bedzone (AZ-A). The distributor (145) may be a ring distributor, pipedistributor, bubble-cap plate distributor, slit-nozzle distributor,tent-grid plate distributor, perforated plate distributor, ring sparger,tree sparger, orthogonal sparger, or any other type of distributor knownin the art.

The classifier (A1A) has an interior (INA) and a gas distributor valve(V91) separates the interior (INA) into a classifier zone (INA1) and agas distribution zone (INA2). The classifier zone (INA1) is above thegas distribution zone (INA2) and the gas distribution zone (INA2) isbelow the classifier zone. The classifier gas (A16) introduced to theclassifier (A1A) via the classifier gas input (A6A) is introduced intothe classifier zone (INA1), below the gas distributor valve (V91), topermit substantially completely even distribution of the gas (A16)through the perforations of the gas distributor valve (V91). Thus, theeven distribution of gas (A16) through the perforations of the closedgas distributor valve (V91) permits the gas (A16) to elutriate the bedmaterial portion from the classifier leaving the inert feedstockcontaminant portion resting upon the perforated surface of the closedgas distributor valve (V91).

The gas distributor valve (V91) has a perforated cross sectional areathat is in contact with the interior (INA) of the classifier (A1A). Thegas distributor valve (V91) may be any conceivable type of valvesuitable for use in the application. We have found that a sliding gatevalve with a perforated gate or blade is most suitable because itslidably completely retracts and permits the classified inert feedstockcontaminants (A19) to be freely transferred from the classifier zone(INA1) through the gas distribution zone (INA2) and drained via theclassifier inert feedstock contaminant output (A9A). However, abutterfly valve with a perforated butterfly disc may also be used aswell, but is not preferred since the stem along which the axis ofperforated valve disc rotates impedes draining since it occupies aportion of the cross sectional area of the classifier interior (INA).

Preferably, the gas distributor valve (V91) has holes, perforations, orpores are on the order of about 10 to 100 microns so as to permit thevalve to be in the closed position and still allow (a) classifier gas(A16) to pass up through the valve (V91), and (b) inert feedstockcontaminants and bed material to not pass down through the valve. Thus,when the gas distributor valve (V91) is in the closed position, the bedmaterial and inert feedstock contaminant mixture (A4A) may rest upon theclosed gas distributor valve (V91). When the classification procedure asdescribed in FIG. 22 is implemented, the classifier gas (A16) isintroduced to the gas distribution zone (INA2) of the classifier (A1A).During classification, the gas (A16) flows up through the pores of theclosed gas distributor valve (V91) and elutriates the bed materialportion for transfer to the first reactor (100) via a riser (A17)leaving the inert feedstock contaminant portion resting upon theperforated surface of the closed gas distributor valve (V91). Thus, inthe configuration of FIG. 21, the positioning of the perforated gasdistributor valve (V91) permits inerts to be transferred from theclassifier zone (INA1) to the gas distribution zone (INA2) withoutopening the inert feedstock contaminant drain valve (V13) to evacuatethe inerts from the classifier (A1A).

FIG. 21 also depicts the classified recycled bed material output (A7A)positioned on the cylindrical outer section of the classifier (A1A).FIG. 21 also depicts the classifier depressurization gas output (A8A)positioned on the upper portion of the classifier zone (INA1), howeverthe gas output (A8A) may also be positioned on the gas distribution zone(INA2).

The master control computer (COMP) may implement automation of thefollowing controllers and their respective valves: mixture transfervalve controller (C9A); classification gas transfer valve controller(C10A); bed material riser recycle transfer valve controller (C11A);depressurization vent valve controller (C12A); inert feedstockcontaminant drain valve controller (C13A); and, the gas distributorvalve controller (C91).

A large objects drain valve (V92) is positioned in between the bedmaterial and inert feedstock contaminant mixture output (A2A) of thefirst reactor (100) and the bed material and inert feedstock contaminantmixture input (A5A) of the classifier (A1A). The large objects drainvalve (V92) prevents large objects, such as agglomerates or broken ordislodged refractory materials to be removed prior to being sent to theclassifier (A1A).

FIG. 21A:

Details of the gas distributor valve (V91) as referred to in FIG. 21 areshown in FIGS. 21A & 21B. FIGS. 21A & 21B depict the gas distributorvalve (V91) as a type of slide-gate valve or through-port valve whichcomprises a well-guided blade (502) passing through both ends of thevalve body (504). The gas distributor valve (V91) is opened and closedby use of an actuator (506) with an integrated controller (C91). Theactuator (506) is connected to the blade (502) via a first clevis (508A)and a first rod (510A) and a second clevis (508B) and a second rod(510B). Packing (512A, 512B) is used as a seal between the blade (502)and valve body (504) on both ends of the valve body (504). The blade(502) has of porous perforations (514) at one end and a hole (516) at anopposite end of the blade (502).

FIG. 21A shows a top-down view of the classifier gas distributor valve(V91) in the closed position. When the gas distributor valve (V91) is inthe closed position, bed material and inert feedstock contaminants mayrest upon the perforations (514) in surface of the valve blade (502)without falling through. Also when the gas distributor valve (V91) is inthe closed position, a classifier gas may pass up through theperforations (514) in the valve blade (502). As gas passes through theperforations (514) in the blade (502), the gas entrains bed materialresting upon the perforations (514) in the blade (502) leaving the inertcontaminants behind resting upon the perforations (514) in the blade(502).

FIG. 21B:

FIG. 21B shows a top-down view of the classifier gas distributor valve(V91) in the open position. In the open position, classified inertfeedstock contaminants pass through the hole (516) in the blade (502)and are subsequently removed from the classifier. They are subsequentlyremoved from the classifier via the inert feedstock contaminant drainvalve (V13A) seen in FIG. 21. It is understood that a slide-gate valvehaving some other design may be used instead. For instance, the slidegate valve (V91) may comprise a fixed hole (516), and a slidable bladehaving a perforated portion which can selectively be positioned over thehole. When transitioning from the closed position to the open positon,the classified inert feedstock contaminants remaining on theperforations are kept in place until they drop through the hole (516)for subsequent removal.

FIG. 22:

FIG. 22 depicts the Classification Valve States as described in FIG. 20further including the operation of a gas distributor valve (V91). FIG.22 is to be used in conjunction with FIG. 21 and depicts a listing ofvalve states that may be used in a variety of methods to operate valvesassociated with one embodiment of a particulate classification vessel(A1A). The only difference between FIG. 20 and FIG. 22 is that the gasdistributor valve (V91) is open during the drain sequence of State 5. Itis preferred to keep the gas distributor valve (V91) closed during allother states. It is preferred to keep the gas distributor valve (V91)closed during the vent sequence of state 4 to prevent erosion of thevalve caused by opening the valve while the classifier interior (INA),classifier zone (INA1), or gas distribution zone (INA2) are aboveatmospheric pressure. However, it may in some instances be permissibleto depart slightly from the sequencing state diagram of FIG. 22 andallow the gas distributor valve (V91) to be open during the ventsequence of state 4.

FIG. 23:

FIG. 23 shows a detailed view of one non-limiting embodiment of a ThirdStage Product Gas Generation Control Volume (CV-3C) and Third StageProduct Gas Generation System (3C) of a three-stage energy-integratedproduct gas generation system (1001) in accordance with FIG. 3 alsoshowing a third reactor (300) equipped with a third interior (301), andalso showing a combustion zone (CZ-A), reaction zone (CZ-B), coolingzone (CZ-C), quench zone (CZ-E), steam drum (350), and valves, sensors,and controllers. FIG. 23 displays a Third Stage Product Gas GenerationSystem (3C) contained within a Third Stage Product Gas GenerationControl Volume (CV-3C) and configured to accept product gas output(3B-OUT1) from a Second Stage Product Gas Generation System (3B). Thethird reactor (300) within the Third Stage Product Gas Generation System(3C) is shown to accept the product gas output (3B-OUT1) as a combinedproduct gas input (3C-IN1).

In some embodiments, as shown in FIG. 23, the third reactor (300) may bea cylindrical, down-flow, non-catalytic, refractory-lined, steelpressure vessel. In embodiments, the third reactor (300) may berectangular. Within the interior (301) of the third reactor (300) areseveral distinct zones that are disposed one after the other in theaxial direction of the interior (301). Four zones exist within theinterior (301) of the third reactor (300): (1) combustion zone (CZ-A),(2) reaction zone (CZ-B), (3) cooling zone (CZ-C), (4) quench zone(CZ-D).

Combustion Zone

The combustion zone (CZ-A) combusts a first hydrocarbon stream (322)with a third reactor oxygen-containing gas (318) to generate acombustion zone output (CZ-AP) or combustion stream. In embodiments, theoxygen-containing gas (318) is introduced to the combustion zone (CZ-A)in superstoichiometric amounts in proportion and relative to the firsthydrocarbon stream (322) so as to substantially, completely combust thefirst hydrocarbon stream (322) to generate CO2 and heat along with anunreacted amount of oxygen-containing gas (318). In embodiments, asuperstoichiometric amount of oxygen is provided to the combustion zone(CZ-A) so that when all of the hydrocarbon stream (322) is burned, thereis still excess oxygen-containing gas (318) left over.

The combustion zone (CZ-A) accepts a third reactor oxygen-containing gas(318) through a third reactor oxygen-containing gas input (320) or anoxygen-containing gas input (3C-IN3). The combustion zone (CZ-A) alsoaccepts a first hydrocarbon stream (322) through a first hydrocarbonstream input (324) or a first hydrocarbon input (3C-IN4). Inembodiments, the first hydrocarbon input (3C-IN4) to the Third StageProduct Gas Generation System (3C) may be a first synthesis hydrocarbonoutput (7-OUT2) such as Fischer Tropsch tail gas transferred from adownstream Synthesis System (7000). In other embodiments, the firsthydrocarbon stream (322) may be natural gas, or naphtha, or off-gas froma downstream Upgrading System (8000). The first hydrocarbon stream(322), in some instances, may be product gas, or even landfill gasincluding a complex mix of different gases created by the action ofmicroorganisms within a landfill.

A first hydrocarbon valve (VC1) may be configured to regulate the flowof the first hydrocarbon stream (322) to the first hydrocarbon streaminput (324). The first hydrocarbon valve (VC1) has a controller (CC1)configured to input or output a signal (XC1). A third reactoroxygen-containing gas valve (VC2) may be configured to regulate the flowof the third reactor oxygen-containing gas (318) through the thirdreactor oxygen-containing gas input (320). The third reactoroxygen-containing gas valve (VC2) has a controller (CC2) configured toinput or output a signal (XC2).

A second hydrocarbon valve (VC3) may be configured to regulate the flowof the second hydrocarbon stream (326) to the second hydrocarbon streaminput (328). The second hydrocarbon valve (VC3) has a controller (CC3)configured to input or output a signal (XC3). A third hydrocarbon valve(VC4) may be configured to regulate the flow of the third hydrocarbonstream (330) to the third hydrocarbon stream input (332). The thirdhydrocarbon valve (VC4) has a controller (CC4) configured to input oroutput a signal (XC4). A third reactor heat transfer medium valve (VC5)may be configured to regulate the flow of the third reactor heattransfer medium (310) to the steam drum (350). The third reactor heattransfer medium valve (VC5) has a controller (CC5) configured to inputor output a signal (XC5).

An oxygen-containing gas (318) is provided to the third reactor (300) sothat the hydrocarbon (322) is reacted at an elevated reactiontemperature sufficient to convert the hydrocarbon (322) substantiallycompletely into carbon dioxide. Therefore a combustion zone output(CZ-AP) includes carbon dioxide, heat, and left over oxygen-containinggas (318), and is discharged from the combustion zone (CZ-A) to thereaction zone (CZ-B) of the third reactor (300). A sufficientoxygen-containing gas (318) is provided to the third reactor (300) sothat excess oxygen-containing gas (318) remains unreacted and exits theburner (346) and thus is also present in the combustion streamdischarged from the combustion zone (CZ-A).

In embodiments, an annulus type burner may be employed to react thefirst hydrocarbon stream (322) with the third reactor oxygen-containinggas (318) through the thermochemical process of combustion. Inembodiments, the burner (346) is a multi-orifice, co-annular, burnerprovided with an arrangement of several passages coaxial with thelongitudinal axis of the burner. Multi-orifice burners comprisingarrangements of annular concentric channels for reacting anoxygen-containing gas (318) with a stream of hydrocarbons (322) may, insome instances, have a reduced area to permit a high velocity stream totake place and result in very rapid and complete reaction of thecombustion stream (CZ-A) with the product gas (302) introduced to thethird reactor (300) to form a reaction stream. The design of the burner(346) is not particularly relevant. Various types of burners may beused. Preferably, a burner is selected that is configured to react acombustible hydrocarbon stream (322) with a stream of oxygen-containinggas (318). The burner may be equipped with an ignitor.

In embodiments, the burner (346) is that of an annulus type. Inembodiments, the burner (346) may be of the type configured to accept ahydrocarbon stream (322) and oxygen-containing gas stream (318) throughconcentric ports, wherein the oxygen-containing gas (318) is injectedinto an annular port, and the hydrocarbon stream (322) is injected tothe central port. The burner (346) ensures rapid and intimate mixing andcombustion of the hydrocarbon (322) with the oxygen-containing gas(318). The hydrocarbon stream (322) and oxygen-containing gas (318) areintroduced under pressure and combustion of the hydrocarbon (322) iscompleted in the burner (346) and terminates at the burner nozzle (347).In embodiments, the burner is constructed such that the reaction betweenthe hydrocarbon (322) and the oxygen-containing gas (318) takes placeentirely outside the burner (346) and only at the burner nozzle (347) soas to provide protection of the burner (346) from overheating and fromdirect oxidation. In embodiments, the burner (346) or the burner nozzle(347) is equipped with a cooling water circuit (not shown).

In embodiments, the burner nozzle (347) may be defined by a restrictionconstituting a reduction in area to provide an increase in velocity ofthe combustion stream (CZ-AP) exiting the burner nozzle (347). Therestriction may even be in some instances a baffle or an impingementplate on which the flame of the combustion stream is stabilized. Theburner nozzle (347) may have a restricting or constricting throat zone,or orifice to accelerate velocity of the combustion stream (CZ-AP) inthe transition from the combustion zone (CZ-A) to the reaction zone(CZ-B). A restriction, orifice, baffle, or impingement surface isadvantageous to shield the combustion zone (CZ-A) from pressurefluctuations of the reaction zone (CZ-B) to mediate operationaldifficulties such as burner oscillation, flash-back, detonation, andblow-out.

In some embodiments, combustion stream (CZ-AP) exiting the burner nozzle(347) may be transferred at velocities within the range of 200 feet perminute (ft/m) to the speed of sound under the existing conditions. Butadvantageously the combustion stream (CZ-AP) that is discharged from thecombustion zone (CZ-A), via the burner nozzle (347), is at a velocitybetween 50 and 300 feet per second (ft/s) and typically less than 200ft/s.

The product gas (302) must not be allowed to remain at high temperaturesfor more than a fraction of a second, or more than a few seconds, thecritical reaction period limits being about 0.0001 second to about 5seconds. Normally it is advantageous to maintain reaction time betweenthe product gas (302) and combustion stream (CZ-AP) of 0.1 to 5.0seconds to sufficiently completely partially oxidize SVOC, VOC, and charinto additional hydrogen and carbon monoxide. Preferably the residencetime of the product gas (302) and combustion stream (CZ-AP) in thereaction zone is about 3 seconds.

The combustion zone output (CZ-AP) is discharged from the combustionzone (CZ-A) to the reaction zone (CZ-B). The combustion stream iscomprised of an intensely hot mixture of carbon dioxide and excessoxygen-containing gas. The heat generated between the combustion of thehydrocarbon (322) with the oxygen-containing gas (318) in turn elevatesthe temperature of the excess unreacted oxygen-containing gas (318)contained within the combustion zone output (CZ-AP) to a temperature upto 1,500° C. (2,732° F.). It is preferred to operate the combustion zone(CZ-A) at about 1,300° C. (2,372° F.). In embodiments, the combustionstream (CZ-AP) exiting the combustion zone (CZ-A) and entering thereaction zone (CZ-B) operates at about temperature can range from about1,100° C. (2,0172° F.) to 1,600° C. (2,912° F.). In embodiments, abaffle or impingement plate might be installed to shield the combustionzone (CZ-A) from the reaction zone (CZ-B).

Combustion occurs in the combustion zone (CZ-A) to generate CO2, H2O,and heat. Heat generated in the combustion zone (CZ-A) elevates thetemperature of the superstoichiometric oxygen-containing gas (318) whichis then transferred to the reaction zone (CZ-B) as an intensely hotcombustion stream (CZ-AP).

In some embodiments, the burner (346) is a Helmholtz pulse combustionresonator. An oxygen-containing gas (318) may be introduced into theouter annular region of the burner (346) and a hydrocarbon (322) may beintroduced into the central section of the burner (346). Thus, theburner (346) may serve to act as an aerodynamic valve, or diode, suchthat self-aspiration of the oxygen-containing gas (318) is effected inresponse to an oscillating pressure in the combustion zone (CZ-A). Aburner (346) may operate as a pulse combustor, and typically operates inthe following manner. A hydrocarbon (322) enters the combustion zone(CZ-A). An oxygen-containing gas (318) enters the combustion zone(CZ-A). An ignition or spark source (not shown) detonates the explosivemixture during start-up. A sudden increase in volume, triggered by therapid increase in temperature and evolution of combustion stream(CZ-AP), pressurizes combustion zone (CZ-A). As the hot combustionstream (CZ-AP) expands, the burner (346) and nozzle (347) form of afluidic diode, permit preferential flow in the direction of the reactionzone (CZ-B). The gaseous combustion stream (CZ-AP), exiting combustionzone (CZ-A), possesses significant momentum. A vacuum is created incombustion zone (CZ-A) due to the inertia of the combustion stream(CZ-A) passing through the burner nozzle (347), and permits only a smallfraction of the combustion stream (CZ-AP) to return to combustion zone(CZ-A), with the balance of the combustion stream (CZ-AP) exitingthrough the nozzle (347). Because the combustion zone (CZ-A) pressure isthen lower than the supply pressure of both the oxygen-containing gas(318) and the hydrocarbon (322), the oxygen-containing gas (318) and thehydrocarbon (322) mixtures are drawn into combustion zone (CZ-A) whereauto-ignition takes place. Again, the burner (346) and nozzle (347)constrains reverse flow, and the cycle begins anew. Once the first cycleis initiated, operation is thereafter self-sustaining orself-aspirating.

A preferred pulse combustor burner (346) used herein, and as notedabove, is based on a Helmholtz configuration with an aerodynamic valve.The pressure fluctuations, which are combustion-induced in the Helmholtzresonator-shaped combustion burner (346), coupled with the fluidicdiodicity of the aerodynamic valve burner (346) and nozzle (347), causea biased flow of the combustion stream (CZ-AP) from the combustion zone(CZ-A), through the nozzle (347) and into the reaction zone (CZ-B). Thisresults in the oxygen-containing gas (318) being self-aspirated by thecombustion zone (CZ-A) and for an average pressure boost to develop inthe combustion zone (CZ-A) to expel the products of combustion at a highaverage flow velocity (typically over 300 ft/s) into and through thenozzle (347).

The production of an intense acoustic wave is an inherent characteristicof pulse combustion. Sound intensity adjacent to the wall of combustionzone (CZ-A) is normally in the range of 110-190 dB. The range may bealtered depending on the desired acoustic field frequency to accommodatethe specific application undertaken by the pulse combustor.

Reaction Zone

The reaction zone (CZ-B) is configured to react a product gas (302)generated in an upstream reactor (100, 200) with the hot excessoxygen-containing gas contained in the combustion stream (CZ-AP) togenerate additional hydrogen and carbon monoxide. The reaction zone(CZ-B) of the third reactor (300) accepts a combined product gas (302)through a combined product gas input (304) or a combined product gasinput (3C-IN1). The combined product gas (302) enters the reaction zone(CZ-B) and is introduced from the product gas output (3B-OUT1) of theSecond Stage Product Gas Generation System (3B). The hot combustionstream (CZ-AP) is transferred from the combustion zone (CZ-A) to thereaction zone (CZ-B) through the burner nozzle (347) at preferably ahigh velocity to realize a stable flame and enhance mixing and reactionbetween the combustion stream (CZ-AP) and the product gas (302).

Mixing and reaction of the combustion stream (CZ-AP) with the productgas (302) entering the third reactor (300) must be thorough and nearlyinstantaneous. Sudden and furious mixing of at least a portion of thefirst reactor product gas (122), or the combined product gas (302), withthe combustion stream (CZ-AP) takes place in the reaction zone (CZ-B) ofthe third reactor (300). As a result, a reaction zone output (CZ-BP) ora reaction stream, is discharged from the reaction zone (CZ-B) to thecooling zone (CZ-C).

The reaction zone (CZ-B) may also accept a second hydrocarbon stream(326) through a second hydrocarbon stream input (328) or a secondhydrocarbon input (3C-IN5). The second hydrocarbon input (3C-IN5) to theThird Stage Product Gas Generation System (3C) may in some instances benaphtha transferred via a first hydrocarbon output (8-OUT2) from adownstream Upgrading System (8000). The reaction zone (CZ-B) may alsoaccept a third hydrocarbon stream (330) through a third hydrocarbonstream input (332) or a third hydrocarbon input (3C-IN6). The thirdhydrocarbon input (3C-IN6) to the Third Stage Product Gas GenerationSystem (3C) may in some instances be an off-gas transferred via a secondhydrocarbon output (8-OUT3) from a downstream Upgrading System (8000).The second hydrocarbon stream input (328) and the third hydrocarbonstream input (332) may be fluidly in communication with the reactionzone (CZ-B) within the interior (301) of the third reactor (300) via acombined hydrocarbon connection (CZC0), combined hydrocarbon transferline (CZC1) and a combined hydrocarbon input (CZC2).

The hot unreacted oxygen-containing gas contained within the combustionstream (CZ-AP) reacts with the product gas (302) from the first reactor(100) and second reactor (200). The hot unreacted oxygen-containing gascontained within the combustion stream (CZ-AP) optionally reacts with asecond hydrocarbon stream (326) and/or the third hydrocarbon stream(330). Intense mixing and exothermic reaction occurs in the reactionzone (CZ-B) between the combustion stream (CZ-AP) and the product gas(302) and hydrocarbons (326, 330). In some instances, near instantaneousblending of the combustion stream (CZ-AP) with the product gas (302)and/or hydrocarbons (326,330) is effectuated. Thus, the reaction zone(CZ-B) also permits the mixing of the combined product gas (302) andhydrocarbons (326, 330) with the intensely hot combustion stream (CZ-AP)to take place.

The reaction zone (CZ-B) permits sufficient residence time forsubstantially complete reaction of the SVOC, VOC and char containedwithin at least a portion of the first reactor product gas (122) to takeplace with the unreacted hot oxygen-containing gas carried through fromthe combustion stream (CZ-AP). The reaction zone (CZ-B) permitssufficient residence time for substantially complete reaction of theSVOC, VOC and char contained within the combined product gas (302) totake place with the unreacted hot oxygen-containing gas carried throughfrom the combustion stream (CZ-AP). The reaction zone (CZ-B) alsopermits sufficient residence time for substantially complete partialoxidation reaction of the carbon and hydrogen contained within thehydrocarbon stream (326, 330) for conversion into product gas.

In embodiments, additional hydrogen and carbon monoxide is generatedfrom the exothermic partial oxidation reaction between the SVOC, VOC,and char contained within the product gas (302) and the hot excessoxygen-containing gas of the combustion stream (CZ-AP). In embodiments,additional hydrogen and carbon monoxide is also generated fromexothermic partial oxidation reaction between hydrocarbon streams (326,330) with the hot excess oxygen-containing gas of the combustion stream(CZ-AP). In embodiments, more hydrogen and carbon monoxide exits thereaction zone (CZ-B) than what enters the reaction zone (CZ-B). Thereaction stream (CZ-BP) is transferred from the reaction zone (CZ-B) tothe cooling zone (CZ-C). In embodiments, a baffle, or impingement plate,might be installed to shield the reaction zone (CZ-B) from the coolingzone (CZ-C).

Cooling Zone

The cooling zone (CZ-C) is configured to transfer heat from the reactionstream (CZ-BP) to a heat transfer medium (310) which can then in turn beused as a reactant (106, 206) in an upstream reactor (100, 200). Thecooling zone (CZ-C) is configured to accept a reaction stream (CZ-BP)from the reaction zone (CZ-B) and remove heat therefrom to in turngenerate a cooling zone output (CZ-CP) or cooled stream. The cooledstream (CZ-CP) leaving the cooling zone (CZ-C) has a lower, reducedtemperature relative to that of the reaction stream (CZ-BP) that entersthe cooling zone (CZ-C) from the reaction zone (CZ-C).

Removal of heat from the reaction stream (CZ-BP) may be accomplished byuse of a third reactor heat exchanger (HX-C) in thermal contact with theinterior (301) of the third reactor (300). More specifically, the thirdreactor heat exchanger (HX-C), in thermal contact with the cooling zone(CZ-C) of the interior (301) of the third reactor (300), indirectlytransfers heat from the reaction stream (CZ-BP) to a third reactor heattransfer medium (310). The third reactor heat exchanger (HX-C) may beany type of heat transfer device known in the art, and is equipped witha heat transfer medium inlet (312) and a heat transfer medium outlet(316). FIG. 23 depicts a heat transfer medium (310) being made availableand introduced to the heat transfer medium inlet (312) on the lowerportion of the cooling zone (CZ-C). FIG. 23 also depicts a heat transfermedium (310) being discharged from the third reactor heat exchanger(HX-C) via an outlet (316) on the upper portion of the cooling zone(CZ-C).

A third reactor heat transfer medium (310) or a third reactor heatexchanger heat transfer medium input (3C-IN2) is made available to theThird Stage Product Gas Generation System (3C). Specifically, thirdreactor heat transfer medium (310) is made available to a steam drum(350) via a steam drum heat transfer medium supply inlet (352). A thirdreactor heat transfer medium valve (VC5), with a controller (CC5) andsignal (XC5) is provided to regulate the flow of the heat transfermedium to the steam drum (350). The heat transfer medium depicted inFIG. 23 is water and liquid phase water is provided to the third reactorheat exchanger (HX-C) from the steam drum (350) at a third reactor heattransfer medium inlet temperature (T0). The steam drum (350) has thirdreactor steam drum pressure (P-C1). In embodiments, the steam drum (350)contains liquid and vapor phase water. A portion of the liquid phasewater is transferred from the steam drum (350) via an outlet (356) and aheat transfer medium conduit (362) to the third reactor heat transfermedium inlet (312).

The steam drum heat transfer medium outlet (356) of the steam drum (350)are in fluid communication with the third reactor heat transfer mediuminlet (312) via a heat transfer medium conduit (362). The steam drumheat transfer medium reactor inlet (354) of the steam drum (350) is influid communication with the third reactor heat transfer medium outlet(316) via a heat transfer medium conduit (364). The steam drum heattransfer medium outlet (358) of the steam drum (350) is in fluidcommunication with the second reactor heat exchanger (HX-B). Morespecifically, the steam drum heat transfer medium outlet (358) of thesteam drum (350) is in fluid communication with the second reactor heattransfer medium inlet (212) via a heat transfer medium conduit (360).Thus, the third reactor heat transfer medium outlet (316) of the thirdreactor heat exchanger (HX-C) is in fluid communication with the secondreactor heat transfer medium inlet (212) of the second reactor heatexchanger (HX-B) via a steam drum (350) and heat transfer conduits (360,364).

FIG. 23 depicts a heat transfer medium (310) being introduced to theinlet (312) of the third reactor heat exchanger (HX-C) via a steam drum.A portion of the liquid phase heat transfer medium contained within thethird reactor heat exchanger (HX-C) accepts heat from the reactionstream (CZ-BP) flowing down through cooling zone (CZ-C) within theinterior (301) of the third reactor (300). At least a portion of theheat transferred from the reaction stream (CZ-BP) to the heat transfermedium (310) generates steam which is then transferred back to the steamdrum (350). The vapor phase heat transfer medium (310) that exits theoutlet (316) of the third reactor heat exchanger (HX-C), and transferredto the steam drum (350) is then routed to the inlet (212) of the secondreactor heat exchanger via a heat transfer medium conduit (360) or asecond reactor heat transfer medium input (3B-IN2) or a third reactorheat transfer medium output (3C-OUT2). Thus, a portion of the thirdreactor heat transfer medium (310) accepts heat from a portion of theheat generated in the third reactor (300) and is ultimately used as (i)heat transfer medium (210) in the second reactor heat exchanger, (ii) areactant (106A, 106B, 106C) in the first reactor (100), and/or (iii) areactant (206A, 206B, 206C) in the second reactor (200).

The Third Stage Product Gas Generation System (3C) outputs a thirdreactor heat transfer medium output (3C-OUT2) to the Second StageProduct Gas Generation System (3B) as a second reactor heat transfermedium input (3B-IN2). A cooling zone output (CZ-CP) or cooled stream isdischarged from the cooling zone (CZ-C) and is introduced to the quenchzone (CZ-D). The cooled stream (CZ-CP) leaving the cooling zone (CZ-C)is lesser in temperature than the reaction stream (CZ-BP) entering thecooling zone (CZ-C).

Quench Zone

The quench zone (CZ-D) is configured to accept a cooling zone output(CZ-CP) or cooled stream, along with a source of third reactor quenchwater (342), and output a quench zone output (CZ-DP) or quenched stream.A source of quench water (342) is introduced to the quench zone (CZ-D)within the interior (301) of the third reactor (300). The quench water(342) is made available to the Third Stage Product Gas Generation System(3C) via a quench water input (3C-IN7).

In embodiments, the quenched stream (CZ-DP) may be synonymous with thethird reactor product gas (334) that is discharged from the thirdreactor (300) via a third reactor product gas output (336). The quenchedthird reactor product gas (334) is evacuated from the Third StageProduct Gas Generation System (3C) via third reactor product gas output(3C-OUT1) and is made available to a downstream Primary Gas Clean UpSystem (4000) via a product gas input (4-IN1). The quench zone (CZ-D) isalso configured to output a third reactor slag (338) via a third reactorslag output (340). The slag (338) may be evacuated from the Third StageProduct Gas Generation System (3C) via a solids output (3C-OUT3).

The quench zone (CZ-D) is optional in the event of the need to maximizethe heat recovery in a downstream Primary Gas Clean Up Heat Exchanger(HX-4) located in a downstream Primary Gas Clean Up Control Volume(CV-4000). In other embodiments, where the quench stream (CZ-DP) isoptional and omitted, the cooled stream (CZ-CP) may be synonymous withthe third reactor product gas (334) that is discharged from the thirdreactor (300) via a third reactor product gas output (336).

Thus, in turn, FIG. 23 depicts a system and process for the partialoxidation of SVOC and VOC contained within a product gas stream,comprising:

-   (a) combusting a hydrocarbon stream with oxygen to form a combustion    stream comprised of CO2, H2O, and oxygen;-   (b) reacting VOC and SVOC within the combustion stream to form a    reaction stream;-   (c) cooling the reaction stream with a heat transfer medium;-   (d) superheating the heat transfer medium in a second reactor heat    exchanger;-   (e) introducing the superheated heat transfer medium to a first    reactor as a reactant; and,-   (f) introducing the superheated heat transfer medium to a second    reactor as a reactant.

Further, FIG. 23 depicts a:

(a) third reactor (300) having a third interior (301) and comprising: acombustion zone (CZ-A) configured to accept both a third reactoroxygen-containing gas (318) through a third reactor oxygen-containinggas input (320) and a first hydrocarbon stream (322) through a firsthydrocarbon stream input (324) and output a combustion zone output(CZ-AP) through a burner (346);

(b) a reaction zone (CZ-C) configured to accept both the product gascreated by the first reactor (100) and product gas created by the secondreactor (200) through a product gas input (304); and react with thecombustion zone output (CZ-AP) to output a reaction zone output (CZ-BP);

(c) a cooling zone (CZ-C) configured to accept a third reactor heattransfer medium (310) through third reactor heat transfer medium inlet(312); and transfer thermal energy from the reaction zone output (CZ-BP)to the third reactor heat transfer medium (310) for output via a thirdreactor heat transfer medium outlet (316) while also outputting acooling zone output (CZ-CP); and

(e) a quench zone (CZ-D) configured to accept a third reactor quenchwater (342) through a third reactor quench water input (344) and releasethird reactor product gas (334) through a third reactor product gasoutput (336).

wherein the combustion zone (CZ-A) is configured to combust at least aportion of the first hydrocarbon stream (322) to generate a combustionzone output (CZ-AP) comprised of a heated stream of oxygen-containinggas, CO2, and H2O; and, wherein the reaction zone (CZ-B) is configuredto react the combustion zone output (CZ-AP) with CH4, unreacted carbonwithin elutriated char, or aromatic hydrocarbons contained withinproduct gas created by both the first reactor (100) and the secondreactor (200) to generate additional carbon monoxide (CO) and hydrogen(H2).

The first reactor product gas (122) has a first H2 to CO ratio and afirst CO to CO2 ratio. The second reactor product gas (222) has a secondH2 to CO ratio and a second CO to CO2 ratio. The third reactor productgas (334) has a third H2 to CO ratio and a third CO to CO2 ratio.

In embodiments, the first H2 to CO ratio is greater than the second H2to CO ratio. In embodiments, the second CO to CO2 ratio is greater thanthe first CO to CO2 ratio. In embodiments, the third H2 to CO ratio islower than both the first H2 to CO ratio and the second H2 to CO ratio.In embodiments, the third CO to CO2 ratio is greater than both the firstCO to CO2 ratio and the second CO to CO2 ratio.

FIG. 24:

FIG. 24 depicts one non-limiting embodiment of a three-stageenergy-integrated product gas generation system (1001) comprised of fourfirst reactors (100A, 100B, 100C, 100D), and four second reactors (200A,200B, 200C, 200D), each with their own separate first solids separationdevice (150A, 150B, 150C, 150D), and second solids separation device(250A, 250B, 250C, 250D), and combined reactor product gas conduits(230A, 230B, 230C, 230D) for feeding into one common third reactor(300).

One common third reactor (300) is utilized to accommodate the flow ofproduct gas from four separate product gas generation systems (1003A,1003B, 1003C, 1003D). The first reactors (100A, 100B, 100C, 100D) withineach product gas generation system (1003A, 1003B, 1003C, 1003D) arespaced apart from one another by a 90 degree angle. Further, sixcarbonaceous material inputs are positioned about the circumference ofeach first reactor (100A, 100B, 100C, 100D). Four of the sixcarbonaceous material inputs to each first reactor (100A, 100B, 100C,100D) are positioned 90 degrees from one another. Two of the sixcarbonaceous material inputs to each first reactor (100A, 100B, 100C,100D) are positioned 180 degrees from one another at angles of 45degrees and 225 degrees leaving the angled positions of 135 degrees and315 degrees vacant where the angle 0 degrees and 360 degrees are at thetwelve-o-clock position also described in FIG. 9.

FIG. 24 depicts a typical 2,000 ton per day (tpd) three-stageenergy-integrated product gas generation system (1001). The 2,000 tpdsystem is made up of four separate first reactors (100A, 100B, 100C,100D) and four separate second reactors (200A, 200B, 200C, 200D). Eachof the four separate first reactors (100A, 100B, 100C, 100D) are eachcapable of accepting 500 tpd of carbonaceous material. Each of the fourseparate second reactors (200A, 200B, 200C, 200D) are configured toaccept and react a portion of the char contained within the firstreactor product gas (122A, 122B, 122C, 122D) to generate four separatestreams of second reactor product gas (222A, 222B, 222C, 222D). Aportion of the four separate streams of second reactor product gas(222A, 222B, 222C, 222D) is then combined with the char depleted firstreactor product gas (126A, 126B, 126C, 126D) evacuated from the firstsolids separation device (150A, 150B, 150C, 150D) to form four separatecombined product gas streams routed to a common third reactor (300) viafour separate combined reactor product gas conduits (230A, 230B, 230C,230D). It is to be understood that any number of combinations andpermutations of first reactors (100A, 100B, 100C, 100D) and separatesecond reactors (200A, 200B, 200C, 200D) and third reactors (300) may beselected to realize a three-stage energy-integrated product gasgeneration system (1001).

FIG. 25:

FIG. 25 shows Product Gas Generation System (3000) of FIG. 1 utilized inthe framework of an entire Refinery Superstructure System (RSS). Inembodiments, the RSS system as shown in FIG. 25 may be configured toemploy the use of the three-stage energy integrated product gasgeneration method as elaborated upon in FIG. 1.

The Refinery Superstructure System (RSS) of FIG. 25 is comprised of a:Feedstock Preparation System (1000) contained within a FeedstockPreparation Control Volume (CV-1000); a Feedstock Delivery System (2000)contained within a Feedstock Delivery Control Volume (CV-2000); a FirstStage Product Gas Generation System (3A) contained within a First StageProduct Gas Generation Control Volume (CV-3A); a Second Stage ProductGas Generation System (3B) contained within a Second Stage Product GasGeneration Control Volume (CV-3B); a Third Stage Product Gas GenerationSystem (3C) contained within a Third Stage Product Gas GenerationControl Volume (CV-3C); a Primary Gas Clean-Up System (4000) containedwithin a Primary Gas Clean-Up Control Volume (CV-4000); a CompressionSystem (5000) contained within a Compression Control Volume (CV-5000); aSecondary Gas Clean-Up System (6000) contained within a Secondary GasClean-Up Control Volume (CV-6000); a Synthesis System (7000) containedwithin a Synthesis Control Volume (CV-7000); and, an Upgrading System(8000) contained within a Upgrading Control Volume (CV-8000).

The Feedstock Preparation System (1000) is configured to accept acarbonaceous material (500) via a carbonaceous material input (1-IN1)and discharge a carbonaceous material output (1-OUT1). Some typicalsequence steps or systems that might be utilized in the FeedstockPreparation System (1000) include, Large Objects Removal, RecyclablesRemoval, Ferrous Metal Removal, Size Reduction, Water Removal,Non-Ferrous Metal Removal, Polyvinyl Chloride Removal, Glass Removal,Size Reduction, and Pathogen Removal.

The Feedstock Delivery System (2000) is configured to accept acarbonaceous material input (2-IN1) from the output (1-OUT1) of theFeedstock Preparation System (1000) and blend the carbonaceous materialfrom the input (2-IN1) with the carbon dioxide input (2-IN2) to realizea carbonaceous material output (2-OUT1). The carbon dioxide input(2-IN2) to the Feedstock Delivery System (2000) is the carbon dioxideoutput (6-OUT2) from the downstream Secondary Gas Clean-Up System(6000). A Feedstock Delivery System CO2 Heat Exchanger (HX-2000) may bepositioned upstream of the carbon dioxide input (2-IN2) to the FeedstockDelivery System (2000) to reduce the temperature of the carbon dioxidetransferred from the downstream Secondary Gas Clean-Up System (6000).The Feedstock Delivery System CO2 Heat Exchanger (HX-2000) has a heattransfer medium (575), such as water, air, or any suitable liquid,vapor, or gas. The HX-2000 heat transfer medium (575) enters the HX-2000via an inlet (525) at a first temperature, and exits HX-2000 via aHX-2000 heat transfer medium outlet (550) at a second, highertemperature. Water or moisture may be removed after HX-2000 cools thecarbon dioxide stream prior to being introduced to the FeedstockDelivery System (2000).

The First Stage Product Gas Generation System (3A) contained within theFirst Stage Product Gas Generation Control Volume (CV-3A) is configuredto accept the carbonaceous material output (2-OUT1) from the FeedstockDelivery System (2000) as a carbonaceous material input (3A-IN1) andreact the carbonaceous material transported through the input (3A-IN1)with a reactant provided by the first reactor reactant input (3A-IN2) togenerate a first reactor product gas output (3A-OUT1). The First StageProduct Gas Generation System (3A) is also equipped with a gas input(3A-IN5) coming from the carbon dioxide output (6-OUT2) of thedownstream Secondary Gas Clean-Up System (6000). The First Stage ProductGas Generation System (3A) is configured to output a solids (3A-OUT3) inthe form of Geldart Group D solids in the form of inert feedstockcontaminants.

The Second Stage Product Gas Generation System (3B) contained within theSecond Stage Product Gas Generation Control Volume (CV-3B) accepts thefirst reactor product gas output (3A-OUT1) as a first reactor productgas input (3B-IN1) and exothermically reacts a portion of the contentsof the first reactor product gas input (3B-IN1) with oxygen-containinggas input (3B-IN3) to generate heat and product gas to be evacuated fromthe Second Stage Product Gas Generation System (3B) via a product gasoutput (3B-OUT1). The Second Stage Product Gas Generation System (3B) isalso equipped with a gas input (3B-IN4) coming from the carbon dioxideoutput (6-OUT2) of the downstream Secondary Gas Clean-Up System (6000).

A second reactor heat exchanger (HX-B) is in thermal contact with theexothermic reaction taking place between at least a portion of the charcontained within the product gas transferred through the first reactorproduct gas input (3B-IN1) with oxygen-containing gas input (3B-IN3)within the Second Stage Product Gas Generation System (3B). The secondreactor heat exchanger (HX-B) is configured to accept a heat transfermedium, such as water, from a second reactor heat transfer medium input(3B-IN2) and transfer heat from the exothermic reaction taking placebetween the Second Stage Product Gas Generation System (3B) to thecontents of the heat transfer medium input (3B-IN2) to result in asecond reactor heat transfer medium output (3B-OUT2). The temperature(T2) of the second reactor heat transfer medium output (3B-OUT2) isgreater than the temperature (T1) of the second reactor heat transfermedium input (3B-IN2). In embodiments, the first reactor reactanttemperature (TR1) is about equal to the second reactor outlettemperature (T2). In embodiments, the first reactor reactant temperature(TR1) is less than the second reactor outlet temperature (T2) due toheat losses in piping while transferring the heat transfer medium fromthe outlet of the second reactor heat exchanger (HX-B) to the FirstStage Product Gas Generation System (3A).

The first reactor reactant input (3A-IN2) is in fluid communication withthe second reactor heat transfer medium output (3B-OUT2) and isconfigured to introduce at least a portion of the contents therein intothe First Stage Product Gas Generation System (3A) to react with thecarbonaceous material (500) to realize a first reactor product gasoutput (3A-OUT1).

The second reactor reactant input (208) is in fluid communication withthe second reactor heat transfer medium output (3B-OUT2) and isconfigured to introduce at least a portion of the contents therein intothe Second Stage Product Gas Generation System (3B) to exothermicallyreact with a portion of the contents of the first reactor product gasinput (3B-IN1) to realize a product gas output (3B-OUT1).

A first reactor heat exchanger (HX-A) is in thermal contact with theFirst Stage Product Gas Generation System (3A) to provide the energy toendothermically react the carbonaceous material (500) with the firstreactor reactant input (3A-IN2) to realize a first reactor product gasoutput (3A-OUT1).

The first reactor heat exchanger (HX-A) is comprised of a fuel input(3A-IN4) and a combustion products output (3A-OUT2) and is configured tocombust the contents of the fuel input (3A-IN4) to indirectly heat thecontents within the First Stage Product Gas Generation System (3A) whichin turn then promotes the endothermic reaction between a portion of thecontents of the first reactor reactant input (3A-IN2) to react with thecarbonaceous material (500) to realize a first reactor product gasoutput (3A-OUT1).

In embodiments, the fuel input (3A-IN4) to the first reactor heatexchanger (HX-A) may be a methane containing gas such as natural gas, asseen in FIG. 25. In embodiments, the fuel input (3A-IN4) to the firstreactor heat exchanger (HX-A) may be provided by the downstreamSynthesis System (7000) as a first synthesis hydrocarbon output (7-OUT2)and may be comprised of Fischer-Tropsch products such as tail gas. Inembodiments, the fuel input (3A-IN4) to the first reactor heat exchanger(HX-A) may be provided by the downstream upgrading System (8000) as afirst hydrocarbon output (8-OUT2) such as naphtha.

The Second Stage Product Gas Generation System (3B) is also configuredto accept a fuel output (4-OUT2) such as char, SVOC, VOC, or solventfrom a downstream Primary Gas Clean-Up System (4000) as a fuel input(3B-IN5).

The Third Stage Product Gas Generation System (3C) contained within theThird Stage Product Gas Generation Control Volume (CV-3C) accepts theproduct gas output (3B-OUT1) from the Second Stage Product GasGeneration System (3B) as a combined product gas input (3C-IN1) andexothermically reacts a portion thereof with an oxygen-containing gasinput (3C-IN3) to generate heat and a third reactor product gas output(3C-OUT1).

A third reactor heat exchanger (HX-C) is in thermal contact with theThird Stage Product Gas Generation System (3C). The third reactor heatexchanger (HX-C) is in thermal contact with the exothermic reactionbetween the combined product gas input (3C-IN1) and theoxygen-containing gas input (3C-IN3). The third reactor heat exchanger(HX-C) is configured to accept a heat transfer medium, such as water orsteam, at a third reactor heat transfer medium inlet temperature (T0),from a third reactor heat transfer medium input (3C-IN2) and transferheat from the exothermic reaction taking place between the Third StageProduct Gas Generation System (3C) to the contents of the heat transfermedium input (3C-IN2) to result in a third reactor heat transfer mediumoutput (3C-OUT2). The third reactor heat transfer medium output(3C-OUT2) is in fluid communication with the second reactor heattransfer medium input (3B-IN2) of the second reactor heat exchanger(HX-B).

The Third Stage Product Gas Generation System (3C) is also configured toaccept a first hydrocarbon input (3C-IN4) from the first synthesishydrocarbon output (7-OUT2) of a downstream Synthesis System (7000)contained within a Synthesis Control Volume (CV-7000). The Third StageProduct Gas Generation System (3C) is also configured to accept a secondhydrocarbon input (3C-IN5) from the first hydrocarbon output (8-OUT2) ofa downstream Upgrading System (8000) contained within an UpgradingControl Volume (CV-8000). The Third Stage Product Gas Generation System(3C) is also configured to accept a third hydrocarbon input (3C-IN6)from the second hydrocarbon output (8-OUT3) of a downstream UpgradingSystem (8000) contained within an Upgrading Control Volume (CV-8000).The first hydrocarbon input (3C-IN4), second hydrocarbon input (3C-IN5),or third hydrocarbon input (3C-IN6) may be reacted in a thermochemicalprocess within the third reactor (300) to generate product gas. TheThird Stage Product Gas Generation System (3C) may also be configured togenerate power from a portion of the third reactor heat transfer mediumoutput (3C-OUT2).

The Primary Gas Clean-Up System (4000) is equipped to accept a productgas input (4-IN1) from the third reactor product gas output (3C-OUT1) ofthe Third Stage Product Gas Generation System (3C). The Primary GasClean-Up System (4000) may also be configured to generate electricityfrom a portion of the product gas through any conventional well-knownsystem such as a gas turbine, combined cycle, and/or steam turbine. ThePrimary Gas Clean-Up System (4000) is configured to reduce thetemperature, remove solids, SVOC, VOC, and water from the product gastransported through the product gas input (4-IN1) to in turn discharge aproduct gas output (4-OUT1). A fuel output (4-OUT2) not only includingVOC, SVOC, char, or solvent, may also be discharged from the Primary GasClean-Up System (4000) and introduced to the Second Stage Product GasGeneration System (3B) as a fuel input (3B-IN5).

The Compression System (5000) accepts the product gas output (4-OUT1) ofthe Primary Gas Clean-Up System (4000) as a product gas input (5-IN1).The Compression System (5000) is configured to accept a product gasinput (5-IN1) and increase its pressure to form a product gas output(5-OUT1) at a greater pressure than the product gas input (5-IN1).

The Secondary Gas Clean-Up System (6000) accepts the product gas output(5-OUT1) from the Compression System (5000) as a product gas input(6-IN1). The Secondary Gas Clean-Up System (6000) is configured toaccept a carbon dioxide laden product gas input (6-IN1) and removecarbon dioxide therefrom to generate both a carbon dioxide output(6-OUT2) and a carbon dioxide depleted product gas output (6-OUT1). TheSecondary Gas Clean-Up System (6000) has a carbon dioxide laden productgas input (6-IN1) and a carbon dioxide depleted product gas output(6-OUT1). The carbon dioxide depleted product gas output (6-OUT1) has alesser amount of carbon dioxide relative to the carbon dioxide ladenproduct gas input (6-IN1). Membrane based carbon dioxide removal systemsand processes are preferred to remove carbon dioxide from product gas,however other alternate systems and methods may be utilized to removecarbon dioxide, not limited to adsorption or absorption based carbondioxide removal systems and processes.

The carbon dioxide depleted product gas output (6-OUT1) is routed to thedownstream Synthesis System (7000) as a product gas input (7-IN1). Thecarbon dioxide output (6-OUT2) may be routed upstream to either to the:Second Stage Product Gas Generation System (3B) as gas input (3B-IN4);First Stage Product Gas Generation System (3A) as a gas input (3A-IN5);or, the Feedstock Delivery System (2000) as a carbon dioxide input(2-IN2). A heat exchanger (HX-2000) may be positioned in between thecarbon dioxide input (2-IN2) of the Feedstock Delivery System (2000) andthe Secondary Gas Clean-Up System (6000) of the carbon dioxide output(6-OUT2).

The Synthesis System (7000) is configured to accept the product gasoutput (6-OUT1) from the Secondary Gas Clean-Up System (6000) as aproduct gas input (7-IN1) and catalytically synthesize a synthesisproduct output (7-OUT1) therefrom. In embodiments, the synthesis systemcontains a catalyst and can produce ethanol, mixed alcohols, methanol,dimethyl ether, Fischer-Tropsch products, or the like.

A synthesis product output (7-OUT1) is discharged from the SynthesisSystem (7000) and is routed to the Upgrading System (8000) where it isaccepted as a synthesis product input (8-IN1).

A first synthesis hydrocarbon output (7-OUT2), including Fischer-Tropschproducts, may be discharged from the Synthesis System (7000) for use asa first hydrocarbon input (3C-IN4) to the third reactor (300) of theupstream Third Stage Product Gas Generation System (3C). In embodiments,a first synthesis hydrocarbon output (7-OUT2), including Fischer-Tropschproducts, may be discharged from the Synthesis System (7000) for use asa fuel input (3A-IN4) in the first reactor first heat exchanger (HX-A)of the upstream First Stage Product Gas Generation System (3A).

The Upgrading System (8000) is configured to generate an upgradedproduct (1500) including renewable fuels and other useful chemicalcompounds, including alcohols, ethanol, gasoline, diesel and/or jetfuel, discharged via an upgraded product output (8-OUT1).

A first hydrocarbon output (8-OUT2), such as naphtha, may be dischargedfrom the Upgrading System (8000) for use as a second hydrocarbon input(3C-IN5) in the third reactor (300) of the upstream Third Stage ProductGas Generation System (3C). A second hydrocarbon output (8-OUT3), suchas off gases, may be discharged from the Upgrading System (8000) for useas a third hydrocarbon input (3C-IN6) in the third reactor (300) of theupstream Third Stage Product Gas Generation System (3C). In embodiments,a first hydrocarbon output (8-OUT2), such as naphtha, may also bedischarged from the Upgrading System (8000) for use as a fuel input(3A-IN4) in the first reactor first heat exchanger (HX-A) of theupstream First Stage Product Gas Generation System (3A). In embodiments,a second hydrocarbon output (8-OUT3), such as off gases, may bedischarged from the Upgrading System (8000) for use as a fuel input(3A-IN4) in the first reactor first heat exchanger (HX-A) of theupstream First Stage Product Gas Generation System (3A).

FIG. 25 discloses a method for converting carbonaceous material into atleast one liquid fuel, the method comprising:

-   (i) combining the carbonaceous material and carbon dioxide in a    feedstock delivery system;-   (ii) producing a third reactor product gas in accordance with the    method of FIG. 2;-   (iii) compressing at least a portion of the third reactor product    gas to thereby form a compressed product gas;-   (iv) removing carbon dioxide from the compressed product gas, and    supplying a first portion of the removed carbon dioxide to the    feedstock delivery system for combining with the carbonaceous    material in step (i);-   (v) reacting the compressed product gas with a catalyst after    removing carbon dioxide; and-   (vi) synthesizing at least one liquid fuel from the compressed    product gas, after reacting the compressed product gas with a    catalyst.

FIG. 25 further discloses method for converting municipal solid waste(MSW) into at least one liquid fuel, the MSW containing Geldart Group Dinert feedstock contaminants, the method comprising:

-   (a) combining the MSW and carbon dioxide in a feedstock delivery    system;-   (b) introducing, into a first interior of a first reactor containing    bed material, steam and the combined MSW and carbon dioxide from the    feedstock delivery system;-   (c) reacting, in the first reactor, the MSW with steam and carbon    dioxide, in an endothermic thermochemical reaction to generate a    first reactor product gas containing char and leaving unreacted    Geldart Group D inert feedstock contaminants in the bed material;-   (d) cleaning the bed material with carbon dioxide to remove said    unreacted Geldart Group D inert feedstock contaminants;-   (e) introducing, into a second reactor containing a second    particulate heat transfer material, an oxygen-containing gas and a    portion of the char;-   (f) reacting, in the second reactor, the char with the    oxygen-containing gas, in an exothermic thermochemical reaction to    generate a second reactor product gas;-   (g) introducing, into a third reactor, an oxygen-containing gas and    the first reactor product gas generated in step (c) and the second    reactor product gas generated in step (f);-   (h) reacting, in the third reactor; the product gas with the    oxygen-containing gas, in an exothermic thermochemical reaction to    generate a third reactor product gas;-   (i) compressing the first and/or second reactor product gas to    thereby form a compressed product gas;-   (j) removing carbon dioxide from the compressed product gas, and    supplying a first portion of the removed carbon dioxide to the    feedstock delivery system for combining with the MSW in step (a);    and supplying a second portion of the removed carbon dioxide to    clean the bed material in step (d);-   (k) reacting the compressed product gas with a catalyst after    removing carbon dioxide; and-   (l) synthesizing at least one liquid fuel from the compressed    product gas, after reacting the compressed product gas with a    catalyst;

wherein:

the Geldart Group D inert feedstock contaminants comprise whole unitsand/or fragments of one or more from the group consisting of allenwrenches, ball bearings, batteries, bolts, bottle caps, broaches,bushings, buttons, cable, cement, chains, clips, coins, computer harddrive shreds, door hinges, door knobs, drill bits, drill bushings,drywall anchors, electrical components, electrical plugs, eye bolts,fabric snaps, fasteners, fish hooks, flash drives, fuses, gears, glass,gravel, grommets, hose clamps, hose fittings, jewelry, key chains, keystock, lathe blades, light bulb bases, magnets, metal audio-visualcomponents, metal brackets, metal shards, metal surgical supplies,mirror shreds, nails, needles, nuts, pins, pipe fittings, pushpins,razor blades, reamers, retaining rings, rivets, rocks, rods, routerbits, saw blades, screws, sockets, springs, sprockets, staples, studs,syringes, USB connectors, washers, wire, wire connectors, and zippers.

FIG. 26:

FIG. 26 shows Product Gas Generation System (3000) of FIG. 1 utilized inan entire Refinery Superstructure (RSS) system further including aPrimary Gas Clean-Up Heat Exchanger (HX-4) in fluid communication withthe second reactor heat transfer medium inlet (212) and configured toremove heat from at least a portion of the product gas input (4-IN1).

FIG. 26 depicts a similar Refinery Superstructure (RSS) system of FIG.25, however does not include a third reactor heat exchanger (HX-C).Instead, the Third Stage Product Gas Generation System (3C) operates ina catalytic mode and utilizes a portion of the third reactor steam input(308) and oxygen-containing gas input (3C-IN3) to regenerate a catalyst(CAT) contained therein.

Further, FIG. 26 indicates the first reactor heat exchanger (HX-A)configured to accept a first synthesis hydrocarbon output (7-OUT2) froma downstream Synthesis System (7000).

FIG. 26 shows Primary Gas Clean-Up Heat Exchanger (HX-4) in fluidcommunication with the second reactor heat transfer medium inlet (212)and is configured to remove heat from at least a portion of the productgas input (4-IN1) provided from the third reactor product gas output(3C-OUT1). The heat transfer medium (210) received by said secondreactor heat transfer medium inlet (212) at the second reactor inlettemperature (T1), is provided by a downstream heat exchanger (HX-4)associated with a primary gas clean-up system configured to clean up theproduct gas.

The product gas input (4-IN1) to the Primary Gas Clean-Up System (4000)comes into thermal contact with the Primary Gas Clean-Up Heat Exchanger(HX-4) to thus effectuate a reduction in temperature to realize aproduct gas output (4-OUT1) from the System (4000) at a temperaturelesser than that of the input (4-IN1).

The Primary Gas Clean-Up Heat Exchanger (HX-4) comprises: a primary gasclean-up heat transfer medium input (4-IN2) configured to receive a heattransfer medium (210) at a primary gas clean-up inlet temperature (T8);and a primary gas clean-up heat transfer medium output (4-OUT3)configured to output the heat transfer medium (210), at a higher,primary gas clean-up outlet temperature (T9), which corresponds to thesecond reactor inlet temperature (T1). The second reactor heat transfermedium inlet (212) is in fluid communication with the primary gasclean-up heat transfer medium output (4-OUT3) and is configured toaccept at least a portion of said heat transfer medium (210) at a secondreactor heat transfer medium input (3B-IN2), at said primary gasclean-up outlet temperature (T1).

A portion of the second reactor heat transfer medium output (3B-OUT2)discharged from the second reactor heat exchanger (HX-B) may in turn betransferred to the Third Stage Product Gas Generation System (3C) toregenerate a catalyst (CAT) contained therein.

FIG. 27:

FIG. 27 further depicts a first reactor (100), first solids separationdevice (150), dipleg (244), solids flow regulator (245), second reactor(200), particulate classification chamber (B1), second solids separationdevice (250), second reactor heat exchanger (HX-B), third reactor (300),third reactor heat exchanger (HX-C), steam drum (350), Primary Gas CleanUp Heat Exchanger (HX-4), venturi scrubber (380), scrubber (384),decanter separator (388), solids separator (398), and a scrubberrecirculation heat exchanger (399). FIG. 27 depicts a three-stageproduct gas generation system (1001) of FIG. 3, further comprising asecond reactor solids output (207) and a first reactor solids input(107) in fluid communication with the second reactor solids output(207), wherein the first reactor solids input (107) is configured toreceive, into the first interior (101), second reactor particulate heattransfer material (205) present in the second interior (201).

The first reactor (100) accepts a carbonaceous material (102) through afirst reactor carbonaceous material input (104). The first reactorreactant (106) is steam transferred from the outlet (216) of the secondreactor heat exchanger (HX-B) at a first reactor reactant temperature(TR1). The first reactor (100) also accepts a first reactor solids input(107) from a second reactor solids output (207), wherein the firstreactor solids input (107) is configured to receive, into the firstinterior (101), second reactor particulate heat transfer material (205)present in the second interior (201). Thus, the second reactorparticulate heat transfer material (205) is used as the first reactorparticulate heat transfer material (105) and the first reactorparticulate heat transfer material (105) is used as the second reactorparticulate heat transfer material (205). A first reactor product gas(122) is discharged from the interior (101) of the first reactor (100)via a first reactor product gas output (124).

FIG. 7 and FIG. 27 show a first reactor (100) configured to accept steamas a reactant (106) at a rate of about 0.125:1 to about 3:1 lb/lb drycarbonaceous material (102). The system of FIG. 7 and FIG. 27 shows afirst reactor (100) configured to accept a carbonaceous material (102)and carbon dioxide mixture so that the carbon dioxide is fed to thefirst reactor (100) at a rate of about 0:1 to about 1:1 lb/lb drycarbonaceous material (102). The system of FIG. 7 and FIG. 8 shows afirst reactor (100) configured to accept an oxygen-containing gas (118)at a rate of about 0:1 to about 0.5:1 lb/lb dry carbonaceous material(102).

Char-carbon refers to the mass fraction of carbon that is containedwithin the char (202) transferred from the first reactor (100) to thesecond reactor (200). In embodiments, the char-carbon contained withinchar (202) transferred from the first reactor (100) to the secondreactor (200) ranges from about 90% carbon to about 10% carbon on aweight basis.

Char-ash refers to the mass fraction of ash that is contained within thechar (202) transferred from the first reactor (100) to the secondreactor (200). In embodiments, the char-ash contained within char (202)transferred from the first reactor (100) to the second reactor (200)ranges from 90% ash to about 10% ash on a weight basis.

The system of FIG. 13 and FIG. 27 shows a second reactor (200)configured to accept steam as a reactant (206) at a rate of about 0:1 toabout 2.5:1 lb/lb char-carbon contained in char (202) fed to the secondreactor (200). The system of FIG. 13 and FIG. 27 shows a second reactor(200) configured to accept an oxygen-containing gas (208) at a rate ofabout 0.5:1 to about 2:1 lb/lb char-carbon contained in char (202) fedto the second reactor (200). The system of FIG. 27 shows a secondreactor (200) configured to accept carbon dioxide (406) at a rate ofabout 0:1 to about 2.5:1 lb/lb char-carbon contained in char (202) fedto the second reactor (200).

In the embodiment of FIG. 27, the first reactor product gas output (124)of the first reactor (100) is in fluid communication with the input(152) of the solids separation device (15) via a riser (130). The firstreactor (100) reacts the carbonaceous material (102) with the reactant(106) in the presence of the bed material (105) to generate product gas(122). The riser (130) is configured to transport a mixture of char(202), bed material (105), and product gas (122) to the first solidsseparation device (150). The first solids separation device (150)separates out the bed material (105) and a portion of the char (202)contained in the first reactor product gas (122) for transfer to thesecond reactor (200).

Product gas, including char and bed material are evacuated from theinterior (101) of the first reactor (100) en route to the input (152) ofthe first solids separation device (150). Solids including char and bedmaterial are separated out in the first solids separation device (150)and are transferred via a dipleg (244) to the input (246) of a solidsflow regulator (245). A char depleted first reactor product gas (126) isevacuated from the first separation gas output (156) of the first solidsseparation device (150) en route to a third reactor (300) via a chardepleted first reactor product gas conduit (128).

In embodiments, the pressure drop across the restriction orifice (RO-B)is typically less than 2 PSIG. In embodiments, the first reactorpressure (P-A) is about 30 PSIG. In embodiments, the second reactorpressure (P-B) is about 28 PSIG. In embodiments, the third reactorpressure is about 26 PSIG. In other embodiments, the first reactor (100)operates at slightly below atmospheric pressure (0.65 to 1 bar or 9.5 to14.5 psia).

FIG. 27 depicts the first reactor temperature (T-A) between about 320°C. and 569.99° C. (608° F. and 1,057.98° F.) and utilizes an endothermichydrous devolatilization thermochemical process within the interior(101). In other embodiments, FIG. 27 may depict the first reactortemperature (T-A) operating between about 570° C. and 900° C. (1,058° F.and 1,652° F.) and utilizing an endothermic steam reformingthermochemical process within the interior (101). In other embodiments,FIG. 27 may depict the first reactor temperature (T-A) operating betweenabout 570° C. and 900° C. (1,058° F. and 1,652° F.) and utilizing anendothermic water-gas shift thermochemical process within the interior(101).

The solids flow regulator (245) accepts a gas (249) through a gas input(248) which prevents backflow and also aides in the transfer of bedmaterial and char from the solids flow regulator (245) to the interior(201) of the second reactor (200). Bed material and char (202) exit thesolids flow regulator (245) through an output (247) and are transportedto a char input (204) on the second reactor (200).

The second reactor (200) has a second interior (201). The second reactorreactant (206) is steam transferred from the outlet (216) of the secondreactor heat exchanger (HX-B) to the reactant inlet (208) of the secondreactor (200). The second reactor (200) accepts an oxygen-containing gas(218) through a second reactor oxygen-containing gas input (220). Thesecond reactor (200) accepts a second reactor carbon dioxide (406)through a second reactor carbon dioxide input (407).

FIG. 27 also depicts the second reactor temperature (T-B) to be between500° C. and 1,400° C. (932° F. and 2,552° F.). The second reactor (200)of FIG. 27 has partial oxidation, steam reforming, water gas shift, anddry reforming thermochemical processes taking place therein.

The second reactor also has a particulate classification chamber (B1)including a mixture transfer valve (V9B), classification gas transfervalve (V10B), bed material riser recycle transfer valve (V11B),depressurization vent valve (V12B), and an inert feedstock contaminantdrain valve (V13B). The particulate classification chamber (B1), orclassifier, has a bed material & inert feedstock contaminant mixtureinput (B5), classifier gas input (B6), classified recycled bed materialoutput (B7), classifier depressurization gas output (B8), and aclassifier inert feedstock contaminant output (B9). The termsclassifier, classifier vessel, particulate classification chamber, andvariations thereof are treated as synonymous throughout thespecification. A table of reference numerals is provided below to avoidconfusion.

The bed material & inert feedstock contaminant mixture input (B5) on theparticulate classification chamber (B1) in fluid communication with thebed material & inert feedstock contaminant mixture output (B2) on thesecond reactor (200) via a mixture transfer conduit (B3). The bedmaterial riser recycle transfer valve (V11B) is located on theclassifier riser (B17) in between the classified recycled bed materialoutput (B7) of the particulate classification chamber (B1) and theclassified recycled bed material input (B27) on the second reactor(200). The depressurization vent valve (V12B) is located approximate tothe classifier depressurization gas output (B8) to control or regulateclassifier depressurization gas (B18) evacuated from the particulateclassification chamber (B1). The inert feedstock contaminant drain valve(V13B) is located approximate to the classifier inert feedstockcontaminant output (B9) to control or regulate classified inertfeedstock contaminants (B19) evacuated from the classifier.

A bed material and inert feedstock contaminant mixture (B4) istransferred from the interior (201) of the second reactor (200) to theinterior of the particulate classification chamber (B1) through themixture transfer conduit (B3). A mixture transfer valve (V9B) isinterposed in the conduit (B3) in between the bed material & inertfeedstock contaminant mixture output (B2) of the second reactor (200)and the mixture input (B5) on the classifier. The bed material and inertfeedstock contaminant mixture (B4) has a bed material portion and aninert feedstock contaminant portion.

The classifier gas input (B6) on the particulate classification chamber(B1) is configured to accept a classifier gas (B16), such as carbondioxide recycled from a downstream Secondary Gas Clean Up System (6000).The classification gas transfer valve (V10B) is located upstream of theclassifier gas input (B6) to start and stop the flow of classifier gas(B16) to the particulate classification chamber (B1). The drag of theclassifier gas (B16) on the bed material portion supplies an upwardforce which counteracts the force of gravity and lifts the classifiedrecycled bed material (B37) through the classified recycled bed materialoutput (B7), classifier riser (B17), and into the second reactor (200)via a classified recycled bed material input (B27). Due to thedependence of gas drag on object size and shape, the bed materialportion in the particulate classification chamber (B1) is sortedvertically and can be separated, recycled, and cleaned in this manner.The classified inert feedstock contaminants (B19) left within theparticulate classification chamber (B1) may be drained via a classifierinert feedstock contaminant output (B9).

FIG. 27 is to be used in conjunction with FIG. 20 which depicts alisting of valve states that may be used in a variety of methods tooperate valves associated with the particulate classification chamber(B1). FIG. 20 identifies five separate discrete valve states of whichany number of states can be selected to result in a sequence of stepsfor the classification of bed material and recovery of inert feedstockcontaminants to prevent defluidization within the second reactor (200).

The char (202) separated out from the first reactor product gas (122) isreacted in the second reactor (200) with the reactant (206), carbondioxide (406), and an oxygen-containing gas (218) to generate a secondreactor product gas (222) evacuated from the second reactor (200) via asecond reactor product gas output (224). Exothermic reactions take placewithin the second reactor (200) between the char (202) and theoxygen-containing gas (218) in the presence of the second reactorparticulate heat transfer material (205).

A second reactor heat exchanger (HX-B) is immersed beneath the fluid bedlevel (L-B) of the second reactor (200) to remove heat from theparticulate heat transfer material (205) and in turn transfer heat tothe second reactor heat transfer medium (210) contained within thesecond reactor heat exchanger (HX-B). A portion of the heated secondreactor heat transfer medium (210) is used as a reactant (106, 206) inthe first reactor (100) and second reactor (200).

The second reactor product gas (222) evacuated from the second reactor(200) through a second reactor product gas output (224) is routed to aninput (252) of the second solids separation device (250). The secondsolids separation device (250) removes solids from the second reactorproduct gas (222) to produce a solids depleted second reactor productgas (226) that is evacuated from the second solids separation device(250) through an output (256) and a solids depleted second reactorproduct gas conduit (228). A solids output (254) on the second solidsseparation device (250) is configured to transfer separated solids (232)from the separation device (250) via a solids transfer conduit (234).

The char depleted first reactor product gas (126) is combined with thesolids depleted second reactor product gas (226) to create a combinedproduct gas (302) that is conveyed to the third reactor (300) through acombined product gas input (304). Generally, it is desirable to operatethe first reactor and second reactor in a superficial fluidizationvelocity range between 0.5 ft/s to about 25.0 ft/s. FIG. 27 depicts thefirst reactor (100) operating in a superficial fluidization velocityrange between 15 ft/s to about 25 ft/s. In embodiments, as in FIG. 3 andFIG. 7, it is preferable to operate the first reactor (100) in asuperficial fluidization velocity range between 0.6 ft/s to about 1.2ft/s. Specifically, in the embodiments of FIG. 3 and FIG. 7 it ispreferable to operate the first reactor in a superficial fluidizationvelocity range between 0.8 ft/s to about 1 ft/s.

In embodiments, as in FIG. 3 and FIG. 13, it is preferable to operatethe second reactor (200) in a superficial fluidization velocity rangebetween 0.2 ft/s to about 0.8 ft/s. Specifically, in the embodiments ofFIGS. 3, 13, and 27, it is preferable to operate the second reactor(200) in a superficial fluidization velocity range between 0.3 ft/s toabout 0.5 ft/s. The second reactor (200) operates at a superficialfluidization velocity sufficient to drive the fine solids from theinterior (201) towards the second solids separation device (250) forremoval.

In embodiments, the carbon conversion rate in the first reactor is inthe range from about 50% to about 100%. In embodiments, the carbonconversion rate in the first reactor (100) is from about 75% to about95%. In embodiments, the when the carbon conversion rate in the firstreactor (100) is from about 75% to about 95%, the second reactor (200)converts the 50% to 99% of the char-carbon transferred from the firstreactor (200) and sent to the second reactor (200). In some embodiments,the second reactor separated solids (232) range from about 0% to about90% carbon and from about 100% to about 10% ash on a weight basis. Insome embodiments, the second reactor separated solids (232) range fromabout 5% to about 30% carbon and from about 95% to about 70% ash on aweight basis.

The embodiment of FIG. 27 depicts a second reactor (200) equipped withparticulate classification chamber (B1). The particulate classificationchamber (B1) may be configured to classify, clean, and recycle bedmaterial back to the interior (201) of the second reactor (200) whileremoving larger objects, such as agglomerates from the system.

In embodiments, it is preferable to use Geldart A particles as bedmaterial in second reactor (200). In other embodiments, it is preferableto use a mixture of Geldart B and Geldart A particles as bed material insecond reactor (200). Thus, the embodiment in FIG. 27 shows the secondreactor particulate heat transfer material (205) being transferred tothe first reactor (100) for use as the first reactor particulate heattransfer material (105).

Agglomeration can take place in the second reactor (200) when thechar-ash introduced with the char (202) to the second reactor (200) isheated above its softening point temperature, and particles sticktogether to form larger or agglomerated particles. Agglomeration ofchar-ash particles together in the second reactor (200) may becompounded by binding or interlocking of two or more fluidized bedparticulates together thus eventually increasing the mean particle sizeof the bed leading to defluidization. As a result growth andaccumulation of agglomerates within the fluidized bed of the secondreactor (200) transitions from proper fluidization to possibleeconomically detrimental defluidization leading to unscheduled processtermination and shut down. To mediate agglomeration in the secondreactor (200), the second reactor (200) can be equipped with at leastone particulate classification chamber (B1) to reliably and consistentlyremove from the system agglomerates from the second interior (201).

Further, since the embodiment shown in FIG. 27 has a first reactor (100)that is not equipped with a particulate classification chamber, all ofthe inert feedstock contaminants introduced to the first reactor (100)are conveyed to the second reactor (200) for removal. Thus, theembodiments shown in FIG. 19 and FIG. 21 may also be applicable to thesecond reactor (200) of FIG. 27.

The third reactor (300) has a third interior (301). The third reactor(300) is configured to accept a combined product gas (302), andpartially oxidize SVOC, VOC, and char contained therein to generate athird reactor product gas (334) and heat. The third reactor has a burner(346) that is configured to accept a first hydrocarbon stream (322),such as a methane containing gas (e.g.—natural gas) via a firsthydrocarbon stream input (324). The third reactor has a burner (346)that is also configured to accept a superstoichiometric third reactoroxygen-containing gas (318) to substantially completely combust thefirst hydrocarbon stream (322) to generate a combustion stream includingCO2, H2O and heat. Left over, unreacted, oxygen-containing gas ispresent in the combustion stream. The combustion stream is passed fromthe burner (346) of the third reactor (300) and partially oxidizes theSVOC, VOC, and char contained within the combined product gas (302) togenerate additional hydrocarbon, carbon monoxide and heat.

The third reactor (300) is also configured to accept second hydrocarbonstream (326) via a second hydrocarbon stream input (328) and a thirdhydrocarbon stream (330) via a third hydrocarbon stream input (332). Thesecond hydrocarbon stream input (328) and third hydrocarbon stream input(332) are in fluid communication with a third reactor via a combinedhydrocarbon connection (CZC0), combined hydrocarbon (CZC1), and acombined hydrocarbon input (CZC2). The second hydrocarbon stream (326),may be naphtha, and the third hydrocarbon stream (330), may be off-gas,both of which may be transferred to the third reactor (300) from adownstream Upgrading System (8000). The carbon and hydrogen containedwithin the second hydrocarbon stream (326) and the third hydrocarbonstream (330) may undergo a thermochemical reaction between theoxygen-containing gas present in the combustion stream transferred fromthe burner (346) to the interior (301) of the third reactor (300) togenerate additional hydrogen, carbon monoxide and heat.

A third reactor heat exchanger (HX-C) is in thermal contact with theinterior (301) of the third reactor (300). The third reactor (HX-C) iscomprised of a third reactor heat transfer medium inlet (312) and athird reactor heat transfer medium outlet (316) through which a thirdreactor heat transfer medium (310) flows. The heat generated by thepartial oxidation reaction between the SVOC, VOC, and char containedwithin the combined product gas (302) and the oxygen-containing gaspresent in the combustion stream leaving the burner (346) is transferredto the third reactor heat transfer medium (310).

A steam drum (350) is configured to accept the heat transfer medium(310) from the third reactor heat transfer medium outlet (316) via aninlet (354) and transfer conduit. FIG. 27 portrays the heat transfermedium (310) transferred to the steam drum (350) to be liquid phasewater. The steam drum is also configured to provide a heat transfermedium (310) to the third reactor heat transfer medium inlet (312) viaan outlet (356) and transfer conduit (362). In embodiments, a supply(353) of liquid phase water for use as the third reactor heat transfermedium (310) is made available to the steam drum (350) via a steam drumheat transfer medium supply inlet (352) and a third reactor heattransfer medium valve (VC5). The steam drum (350) is equipped with apressure sensor (370) and a level sensor (372).

The pressure sensor (370) with an integrated steam pressure controlvalve (366) maintain the steam drum (350) at a user-defined pressure andsteam is discharged through a steam outlet (358) and conduit (360) asnecessary to maintain a desired steam drum (350) operating pressure. Aportion of the steam evacuated form the steam drum (350) is used as thesecond reactor heat transfer medium (210) and is routed to the inlet(212) of the second reactor heat exchanger (HX-B). A portion of thesteam evacuated from the steam drum (350) may be routed elsewhere thanthe inlet (212) of the second reactor heat exchanger (HX-B) via aconduit (365).

A portion of the third reactor heat transfer medium (310) is used as thesecond reactor heat transfer medium (210). The second reactor heattransfer medium enters the inlet (212) of the second reactor heatexchanger (HX-B) at a first temperature T1. Heat from the interior (201)of the second reactor (200) is transferred through the second reactorheat exchanger (HX-B) and into the second reactor heat transfer medium(210). The second reactor heat transfer medium (210) is discharged fromthe outlet (216) of the second reactor heat exchanger (HX-B) and entersthe first reactor (100) for use as a reactant (106). The first reactorreactant (106) enters the interior (101) of the first reactor (100) at afirst reactor reactant temperature (TR1), that is greater than thetemperature of the heat transfer medium (210) entering the secondreactor heat exchanger, at a first inlet temperature (T1). Thus, aportion of the third reactor heat transfer medium (310) is used as thereactant (206) in the second reactor (200). And a portion of the thirdreactor heat transfer medium (310) is used as the reactant (106) in thefirst reactor (200).

The third reactor (300) is configured to output a third reactor slag(338) via a third reactor slag output (340). The third reactor isconfigured to output a third reactor product gas (334) from a thirdreactor product gas output (336) to the inlet (373) of a Primary GasClean Up Heat Exchanger (HX-4). The Primary Gas Clean Up Heat Exchanger(HX-4) has a product gas inlet (373) for accepting a third reactorproduct gas (334) and a product gas outlet (375) for discharging theproduct gas at a reduced temperature. The Primary Gas Clean Up HeatExchanger (HX-4) is configured to remove heat from the third reactorproduct gas (334) to a heat transfer medium flowing from the HeatExchanger (HX-4) from the heat transfer medium inlet (376) to the heattransfer medium outlet (377).

A product gas outlet conduit (378) is positioned on the product gasoutlet (375) of the Primary Gas Clean Up Heat Exchanger (HX-4) and isconfigured to transfer the third reactor product gas to the inlet (379)of a venturi scrubber (380). The Venturi Scrubber operates at atemperature below the SVOC condensation temperature and below thedew-point of the excess steam contained within the product gas thereforecondensing any SVOC and excess steam out into a liquid phase.

Solid char particulates entrained within the product gas come intocontact with water provided by a venturi scrubber transfer conduit(404), and solvent provided by a venturi scrubber transfer conduit(393), at the divergent section of the venturi scrubber and said solidchar particulates act as a nuclei for excess steam condensation and aredisplaced from the vapor phase and into the liquid phase. Connection X8indicates water being transferred from water pump (394) pump discharge(395) to the venturi scrubber (380).

A mixture comprising product gas, SVOC, solids, solvent and water, isrouted to the lower section of the scrubber (384) via a venturi scrubberproduct gas outlet conduit (382). The venturi scrubber product gasoutlet (381) of the venturi scrubber (380) and the product gas inlet(383) of the scrubber (384) are in fluid communication via a venturiscrubber product gas outlet conduit (382).

The scrubber (384) serves as an entrainment separator for the venturiscrubber and is configured to receive the product gas, SVOC, solids,solvent and water and separately output a water and solids depletedproduct gas stream and a second mixture comprising SVOC, solids, solventand water. The scrubber (384) also serves to capture one or more ofother contaminants present including but not limited to HCl, HCN, NH₃,H₂S, and COS. A water and solids depleted product gas stream isevacuated from the scrubber (384) via a product gas outlet (385) andoutlet conduit (386). Thus, the product gas emanating from the scrubber(384) has a depleted amount of solids and water relative to the productgas that is discharged from the third rector (300).

The scrubber (384), is preferably a vertically oriented cylindrical, orrectangular, pressure vessel having a lower section, and an uppersection, along with a central section that contains a quantity of packedmedia either comprising raschig rings, pall rings, berl saddles, intaloxpacking, metal structured grid packing, hollow spherical packing, highperformance thermoplastic packing, structured packing, synthetic wovenfabric, or ceramic packing, or the like, wherein media is supported upona suitable support grid system commonplace to industrial chemicalequipment systems. The upper section of the scrubber (384) preferablycontains a demister to enhance the removal of liquid droplets entrainedin a vapor stream and to minimize carry-over losses of the sorptionliquid. This demister is also positioned above the scrubber spray nozzlesystem, comprised of a plurality of spray nozzles, or spray balls, thatintroduce and substantially equally distribute the scrubbing absorptionliquid to the scrubber onto the scrubber's central packing section so itmay gravity-flow down through the scrubber central section.

As the product gas passes up through the internal packing of thescrubber (384), excess steam within the product gas comes into intimatecontact with water provided by conduit (405) and solvent provided byconduit (392). The water provided by conduit (405) is cooled prior tobeing introduced to the upper section of the scrubber (384) through thescrubber spray nozzle system. Steam is condensed into a liquid phasebefore being discharged from the scrubber (384) via the underflowdowncomer (387). A separator (388), such as a decanter, is positioned toaccept the flow of SVOC, solids, solvent and water from the downcomer(387). In embodiments, a separator (388) is configured to receive themixture from downcomer (387) and separate the water within the mixturebased upon immiscibility so that the SVOC, solids and solvent collecttogether to form a mixture above the water within the separator (388).The decanter separator (388) is further configured to separately outputthe water and the SVOC, solids and solvent mixture. The separator (388)may be equipped with a level sensor (389).

In embodiments, a process fluid (403), such as water, sodium hydroxide,or a dispersant, such as Nalco 3D TRA5AR® 3DT120, may be added to thescrubber. The Nalco Dispersant (3DT120) is used as a declogger toprevent calcium-rich particles from depositing on the pipe wall andplugging the venturi-gas cooler piping.

Through a pump discharge (391), the solvent pump (390) is configured totransfer SVOC, solids and solvent to the second reactor (200) as fuel(262) via a fuel input (264). The solvent pump is also configured totransfer the SVOC, solids and solvent to the venturi scrubber (380) viaa venturi scrubber transfer conduit (393). The solvent pump is alsoconfigured to transfer the SVOC, solids and solvent to the scrubber(384) via a scrubber transfer conduit (392).

Intimate gas to liquid contact within the scrubber (384) allows for thesolvent to both, absorb SVOC from the syngas (if any), and enable solidcarbon (if any), and solid ash, to become oleophilic and hydrophobicpermitting said solids to become suspended within the solvent or waterbefore both the solvent and carbon are discharged from the scrubber(384).

A heat exchanger (399) is installed in the water pump discharge (395)line after the solids separator (398). The heat exchanger (399) ispreferably of the shell and tube type heat exchanger, wherein syngassteam condensate transferred to scrubbing operations resides on thetube-side, and a cooling water supply (401), and a cooling water return(402), communicate with the shell-side of the heat exchanger to fulfillthe heat transfer requirements necessary to indirectly remove heat fromthe tube-side steam condensate recirculation scrubbing liquid.

It will be appreciated that the foregoing examples, given for purposesof illustration, are not to be construed as limiting the scope of thisdisclosure. Although only a few exemplary embodiments of this disclosurehave been described in detail above, those skilled in the art willreadily appreciate that many variation of the theme are possible in theexemplary embodiments without materially departing from the novelteachings and advantages of this disclosure. Accordingly, all suchmodifications are intended to be included within the scope of thisdisclosure that is defined in the following claims and all equivalentsthereto. Further, it is recognized that many embodiments may beconceived in the design of a given system that do not achieve all of theadvantages of some embodiments, yet the absence of a particularadvantage shall not be construed to necessarily mean that such anembodiment is outside the scope of the present disclosure.

Thus, specific compositions and methods of a three-stageenergy-integrated product gas generation system have been disclosed. Itshould be apparent, however, to those skilled in the art that many moremodifications besides those already described are possible withoutdeparting from the inventive concepts herein. The inventive subjectmatter, therefore, is not to be restricted except in the spirit of thedisclosure. Moreover, in interpreting the disclosure, all terms shouldbe interpreted in the broadest possible manner consistent with thecontext. In particular, the terms “comprises” and “comprising” should beinterpreted as referring to elements, components, or steps in anon-exclusive manner, indicating that the referenced elements,components, or steps may be present, or utilized, or combined with otherelements, components, or steps that are not expressly referenced.

Although the foregoing text sets forth a detailed description ofnumerous different embodiments of the disclosure, it should beunderstood that the scope of the disclosure is defined by the words ofthe claims set forth at the end of this patent. The detailed descriptionis to be construed as exemplary only and does not describe everypossible embodiment of the disclosure because describing every possibleembodiment would be impractical, if not impossible. Numerous alternativeembodiments could be implemented, using either current technology ortechnology developed after the filing date of this patent, which wouldstill fall within the scope of the claims defining the disclosure.

Thus, many modifications and variations may be made in the techniquesand structures described and illustrated herein without departing fromthe spirit and scope of the present disclosure. Accordingly, it shouldbe understood that the methods and apparatus described herein areillustrative only and are not limiting upon the scope of the disclosure.

Unless the context dictates the contrary, all ranges set forth hereinshould be interpreted as being inclusive of their endpoints, andopen-ended ranges should be interpreted to include commerciallypractical values. Similarly, all lists of values should be considered asinclusive of intermediate values unless the context indicates thecontrary.

The recitation of ranges of values herein is merely intended to serve asa shorthand method of referring individually to each separate valuefalling within the range. Unless otherwise indicated herein, eachindividual value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided with respectto certain embodiments herein is intended merely to better illuminatethe disclosure and does not pose a limitation on the scope of thedisclosure otherwise claimed. No language in the specification should beconstrued as indicating any non-claimed element essential to thepractice of the disclosure.

Groupings of alternative elements or embodiments of the disclosuredisclosed herein are not to be construed as limitations. Each groupmember can be referred to and claimed individually or in any combinationwith other members of the group or other elements found herein. One ormore members of a group can be included in, or deleted from, a group forreasons of convenience and/or patentability. When any such inclusion ordeletion occurs, the specification is herein deemed to contain the groupas modified thus fulfilling the written description of all Markushgroups used in the appended claims.

It should be apparent to those skilled in the art that many moremodifications besides those already described are possible withoutdeparting from the inventive concepts herein. The inventive subjectmatter, therefore, is not to be restricted except in the spirit of theappended claims. Moreover, in interpreting both the specification andthe claims, all terms should be interpreted in the broadest possiblemanner consistent with the context. In particular, the terms “comprises”and “comprising” should be interpreted as referring to elements,components, or steps in a non-exclusive manner, indicating that thereferenced elements, components, or steps may be present, or utilized,or combined with other elements, components, or steps that are notexpressly referenced. Where the specification claims refers to at leastone of something selected from the group consisting of A, B, C . . . andN, the text should be interpreted as requiring only one element from thegroup, not A plus N, or B plus N, etc.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although any methods andmaterials similar or equivalent to those described herein can also beused in the practice or testing of the present invention, a limitednumber of the exemplary methods and materials are described herein.

It must be noted that as used herein and in the appended claims, thesingular forms “a”, “an”, and “the” include plural referents unless thecontext clearly dictates otherwise.

LISTING OF REFERENCE NUMERALS

-   first reactor (100)-   first reactor (100A)-   first reactor (100B)-   first reactor (100C)-   first reactor (100D)-   first interior (101)-   carbonaceous material (102)-   carbonaceous material (102A)-   carbonaceous material (102B)-   carbonaceous material (102C)-   carbonaceous material (102D)-   carbonaceous material (102E)-   carbonaceous material (102F)-   first reactor carbonaceous material input (104)-   first reactor first carbonaceous material input (104A)-   first reactor second carbonaceous material input (104B)-   first reactor third carbonaceous material input (104C)-   first reactor fourth carbonaceous material input (104D)-   first reactor fifth carbonaceous material input (104E)-   first reactor sixth carbonaceous material input (104F)-   first reactor particulate heat transfer material (105)-   first reactor reactant (106)-   first reactor dense bed zone reactant (106A)-   first reactor feed zone reactant (106B)-   first reactor splash zone reactant (106C)-   first reactor reactant input (108)-   first reactor dense bed zone reactant input (108A)-   first reactor feed zone reactant input (108B)-   first reactor splash zone reactant input (108C)-   first reactor solids input (107)-   first reactor reactant input (108)-   first reactor first heat exchanger fuel (110A)-   first reactor second heat exchanger fuel (110B)-   first reactor third heat exchanger fuel (110C)-   first reactor fourth heat exchanger fuel (110D)-   first reactor heat exchanger fuel (110)-   first reactor heat exchanger fuel inlet (112)-   first reactor first heat exchanger fuel inlet (112A)-   first reactor second heat exchanger fuel inlet (112B)-   first reactor third heat exchanger fuel inlet (112C)-   combined combustion stream (114)-   first reactor first heat exchanger combustion stream (114A)-   first reactor second heat exchanger combustion stream (114B)-   first reactor third heat exchanger combustion stream (114C)-   first reactor fourth heat exchanger combustion stream (114D)-   heat exchanger combustion stream outlet (116)-   first reactor first heat exchanger combustion stream outlet (116A)-   first reactor second heat exchanger combustion stream outlet (116B)-   first reactor third heat exchanger combustion stream outlet (116C)-   first reactor fourth heat exchanger combustion stream outlet (116D)-   first reactor oxygen-containing gas (118)-   first reactor dense bed zone oxygen-containing gas (118A)-   first reactor feed zone oxygen-containing gas (118B)-   first reactor splash zone oxygen-containing gas (118C)-   first reactor oxygen-containing gas input (120)-   first reactor dense bed zone oxygen-containing gas input (120A)-   first reactor feed zone oxygen-containing gas input (120B)-   first reactor splash zone oxygen-containing gas input (120C)-   first reactor product gas (122)-   first reactor product gas (122A)-   first reactor product gas (122A1)-   first reactor product gas (122A2)-   first reactor product gas (122B)-   first reactor product gas (122C)-   first reactor product gas (122D)-   first reactor product gas output (124)-   internal cyclone (125)-   char depleted first reactor product gas (126)-   char depleted first reactor product gas (126A)-   char depleted first reactor product gas (126A1)-   char depleted first reactor product gas (126A2)-   char depleted first reactor product gas (126B)-   char depleted first reactor product gas (126C)-   char depleted first reactor product gas (126D)-   char depleted first reactor product gas conduit (128)-   char depleted first reactor product gas conduit (128A1)-   char depleted first reactor product gas conduit (128A2)-   riser (130)-   distributor (145)-   first solids separation device (150)-   first solids separation device (150A)-   first solids separation device (150A1)-   first solids separation device (150A2)-   first solids separation device (150B)-   first solids separation device (150C)-   first solids separation device (150D)-   first separation input (152)-   first separation input (152A1)-   first separation input (152A2)-   first separation char output (154)-   first separation char output (154A1)-   first separation char output (154A2)-   first separation gas output (156)-   first separation gas output (156A1)-   first separation gas output (156A2)-   auxiliary heat exchanger combustion stream inlet (160)-   auxiliary heat exchanger heat transfer medium (164)-   auxiliary heat exchanger heat transfer medium inlet (166)-   auxiliary heat exchanger combustion stream outlet (167)-   auxiliary heat exchanger heat transfer medium outlet (168)-   auxiliary heat exchanger heat transfer medium outlet conduit (170)-   third reactor heat transfer medium auxiliary conduit (171)-   steam turbine (172)-   generator (173)-   combined heat transfer medium conduit (174)-   power (175)-   second reactor (200)-   second reactor (200A)-   second reactor (200B)-   second reactor (200C)-   second reactor (200D)-   second interior (201)-   char (202)-   char (202A)-   char (202B)-   char (202C)-   char (202D)-   second reactor char input (204)-   second reactor first char input (204A)-   second reactor second char input (204B)-   second reactor third char input (204C)-   second reactor fourth char input (204D)-   second reactor particulate heat transfer material (205)-   second reactor reactant (206)-   second reactor dense bed zone reactant (206A)-   second reactor feed zone reactant (206B)-   second reactor splash zone reactant (206C)-   second reactor solids output (207)-   second reactor reactant input (208)-   second reactor dense bed zone reactant input (208A)-   second reactor feed zone reactant input (208B)-   second reactor splash zone reactant input (208C)-   second reactor heat transfer medium (210)-   second reactor heat transfer medium inlet (212)-   second reactor heat transfer medium outlet (216)-   second reactor oxygen-containing gas (218)-   second reactor dense bed zone oxygen-containing gas (218A)-   second reactor feed zone oxygen-containing gas (218B)-   second reactor splash zone oxygen-containing gas (218C)-   second reactor oxygen-containing gas input (220)-   second reactor dense bed zone oxygen-containing gas input (220A)-   second reactor feed zone oxygen-containing gas input (220B)-   second reactor splash zone oxygen-containing gas input (220C)-   second reactor product gas (222)-   second reactor product gas (222A)-   second reactor product gas (222B)-   second reactor product gas (222C)-   second reactor product gas (222D)-   second reactor product gas output (224)-   second internal cyclone (225)-   solids depleted second reactor product gas (226)-   solids depleted second reactor product gas conduit (228)-   combined reactor product gas conduit (230)-   combined reactor product gas conduit (230A)-   combined reactor product gas conduit (230B)-   combined reactor product gas conduit (230C)-   combined reactor product gas conduit (230D)-   second reactor separated solids (232)-   solids transfer conduit (234)-   riser (236)-   riser connection (238)-   riser conveying fluid (240)-   terminal portion (242)-   dipleg (244)-   dipleg (244A)-   dipleg (244B)-   solids flow regulator (245)-   first solids flow regulator (245A)-   second solids flow regulator (245B)-   solids flow regulator solids input (246)-   first solids flow regulator solids input (246A)-   second solids flow regulator solids input (246B)-   solids flow regulator solids output (247)-   first solids flow regulator solids output (247A)-   second solids flow regulator solids output (247B)-   third solids flow regulator solids output (247C)-   fourth solids flow regulator solids output (247D)-   solids flow regulator gas input (248)-   solids flow regulator gas (249)-   second solids separation device (250)-   second solids separation device (250A)-   second solids separation device (250B)-   second solids separation device (250C)-   second solids separation device (250D)-   second separation input (252)-   second separation solids output (254)-   second separation gas output (256)-   fuel (262)-   fuel input (264)-   third reactor (300)-   third interior (301)-   combined product gas (302)-   first reactor product gas input (303)-   combined product gas input (304)-   second reactor product gas input (305)-   third reactor steam input (308)-   third reactor heat transfer medium (310)-   third reactor heat transfer medium inlet (312)-   third reactor heat transfer medium outlet (316)-   third reactor oxygen-containing gas (318)-   third reactor oxygen-containing gas input (320)-   first hydrocarbon stream (322)-   first hydrocarbon stream input (324)-   second hydrocarbon stream (326)-   second hydrocarbon stream input (328)-   third hydrocarbon stream (330)-   third hydrocarbon stream input (332)-   third reactor product gas (334)-   third reactor product gas output (336)-   third reactor slag (338)-   third reactor slag output (340)-   third reactor quench water (342)-   third reactor quench water input (344)-   impingement surface (345)-   burner (346)-   burner nozzle (347)-   in-flow header (348)-   out-flow header (349)-   steam drum (350)-   tubes (351)-   steam drum heat transfer medium supply inlet (352)-   supply (353)-   steam drum heat transfer medium reactor inlet (354)-   steam drum heat transfer medium outlet (356)-   steam outlet (358)-   heat transfer medium conduit (360)-   heat transfer medium conduit (362)-   heat transfer medium conduit (364)-   steam outlet conduit (365)-   steam pressure control valve (366)-   pressure sensor (370)-   level sensor (372)-   product gas inlet (373)-   product gas outlet (375)-   heat transfer medium inlet (376)-   heat transfer medium outlet (377)-   product gas outlet conduit (378)-   venturi scrubber product gas inlet (379)-   venturi scrubber (380)-   venturi scrubber product gas outlet (381)-   venturi scrubber product gas outlet conduit (382)-   scrubber product gas inlet (383)-   scrubber (384)-   scrubber product gas outlet (385)-   scrubber product gas outlet conduit (386)-   downcomer (387)-   separator (388)-   level sensor (389)-   solvent pump (390)-   pump discharge (391)-   scrubber transfer conduit (392)-   venturi scrubber transfer conduit (393)-   water pump (394)-   pump discharge (395)-   valve (396)-   condensate discharge conduit (397)-   separator (398)-   heat exchanger (399)-   cooling water supply (401)-   cooling water return (402)-   process fluid (403)-   venturi scrubber transfer conduit (404)-   scrubber transfer conduit (405)-   second reactor carbon dioxide (406)-   second reactor carbon dioxide input (407)-   carbonaceous material (500)-   classifier gas distributor valve cross-sectional view (X500)-   blade (502)-   valve body (504)-   actuator (506)-   clevis (508A, 508B)-   rod (510A, 510B)-   packing (512A, 512B)-   perforations (514)-   hole (516)-   HX-2000 heat transfer medium inlet (525)-   HX-2000 heat transfer medium outlet (550)-   HX-2000 heat transfer medium (575)-   Feedstock Preparation System (1000)-   three-stage energy-integrated product gas generation system (1001)-   product gas generation and particulate classification system (1002)-   product gas generation system (1003)-   product gas generation system (1003A)-   product gas generation system (1003B)-   product gas generation system (1003C)-   product gas generation system (1003D)-   upgraded product (1500)-   Feedstock Delivery System (2000)-   Product Gas Generation System (3000)-   Primary Gas Clean Up System (4000)-   Compression System (5000)-   Secondary Gas Clean Up System (6000)-   Synthesis System (7000)-   Upgrading System (8000)-   carbonaceous material input (1-IN1)-   carbonaceous material output (1-OUT1)-   carbonaceous material input (2-IN1)-   carbon dioxide input (2-IN2)-   carbonaceous material output (2-OUT1)-   First Stage Product Gas Generation System (3A)-   carbonaceous material input (3A-IN1)-   first reactor reactant input (3A-IN2)-   oxygen-containing gas input (3A-IN3)-   fuel input (3A-IN4)-   gas input (3A-IN5)-   first reactor product gas output (3A-OUT1)-   combustion products output (3A-OUT2)-   solids (3A-OUT3)-   vent (3A-OUT4)-   Second Stage Product Gas Generation System (3B)-   first reactor product gas input (3B-IN1)-   second reactor heat transfer medium input (3B-IN2)-   oxygen-containing gas input (3B-IN3)-   gas input (3B-IN4)-   fuel input (3B-IN5)-   combustion products input (3B-IN6)-   product gas output (3B-OUT1)-   second reactor heat transfer medium output (3B-OUT2)-   solids output (3B-OUT3)-   Third Stage Product Gas Generation System (3C)-   combined product gas input (3C-IN1)-   third reactor heat exchanger heat transfer medium input (3C-IN2)-   oxygen-containing gas input (3C-IN3)-   first hydrocarbon input (3C-IN4)-   second hydrocarbon input (3C-IN5)-   third hydrocarbon input (3C-IN6)-   quench water input (3C-IN7)-   steam input (3C-IN8)-   third reactor product gas output (3C-OUT1)-   third reactor heat transfer medium output (3C-OUT2)-   solids output (3C-OUT3)-   carbonaceous material input (3-IN1)-   product gas output (3-OUT1)-   product gas input (4-IN1)-   primary gas clean up heat transfer medium input (4-IN2)-   product gas output (4-OUT1)-   fuel output (4-OUT2)-   primary gas clean up heat transfer medium output (4-OUT3)-   product gas input (5-IN1)-   product gas output (5-OUT1)-   product gas input (6-IN1)-   product gas output (6-OUT1)-   carbon dioxide output (6-OUT2)-   product gas input (7-IN1)-   synthesis product output (7-OUT1)-   first synthesis hydrocarbon output (7-OUT2)-   synthesis product input (8-IN1)-   upgraded product output (8-OUT1)-   first hydrocarbon output (8-OUT2)-   second hydrocarbon output (8-OUT3)-   dense bed zone (AZ-A)-   dense bed zone steam/oxygen connection (AZA0)-   dense bed zone steam/oxygen (AZA1)-   dense bed zone steam/oxygen input (AZA2)-   feed zone (AZ-B)-   feed zone steam/oxygen connection (AZB0)-   feed zone steam/oxygen (AZB1)-   first feed zone steam/oxygen input (AZB2)-   second feed zone steam/oxygen input (AZB3)-   third feed zone steam/oxygen input (AZB4)-   fourth feed zone steam/oxygen input (AZB5)-   fifth feed zone steam/oxygen input (AZB6)-   sixth feed zone steam/oxygen input (AZB7)-   splash zone (AZ-C)-   splash zone steam/oxygen connection (AZC0)-   splash zone steam/oxygen (AZC1)-   first splash zone steam/oxygen input (AZC2)-   second splash zone steam/oxygen input (AZC3)-   third splash zone steam/oxygen input (AZC4)-   fourth splash zone steam/oxygen input (AZC5)-   fifth splash zone steam/oxygen input (AZC6)-   sixth splash zone steam/oxygen input (AZC7)-   seventh splash zone steam/oxygen input (AZC8)-   eighth splash zone steam/oxygen input (AZC9)-   dense bed zone (BZ-A)-   dense bed zone steam/oxygen connection (BZA0)-   dense bed zone steam/oxygen (BZA1)-   dense bed zone steam/oxygen (BZA2)-   feed zone (BZ-B)-   feed zone steam/oxygen connection (BZB0)-   feed zone steam/oxygen (BZB1)-   feed zone steam/oxygen input (BZB2)-   feed zone steam/oxygen input (BZB3)-   feed zone steam/oxygen input (BZB4)-   feed zone steam/oxygen input (BZB5)-   splash zone (BZ-C)-   splash zone steam/oxygen connection (BZC0)-   splash zone steam/oxygen (BZC1)-   splash zone steam/oxygen input (BZC2)-   splash zone steam/oxygen input (BZC3)-   splash zone steam/oxygen input (BZC4)-   splash zone steam/oxygen input (BZC5)-   Feedstock Preparation Control Volume (CV-1000)-   Feedstock Delivery Control Volume (CV-2000)-   Product Gas Generation Control Volume (CV-3000)-   First Stage Product Gas Generation Control Volume (CV-3A)-   Second Stage Product Gas Generation Control Volume (CV-3B)-   Third Stage Product Gas Generation Control Volume (CV-3C)-   Primary Gas Clean Up Control Volume (CV-4000)-   Compression Control Volume (CV-5000)-   Secondary Gas Clean Up Control Volume (CV-6000)-   Synthesis Control Volume (CV-7000)-   Upgrading Control Volume (CV-8000)-   combustion zone (CZ-A)-   combustion zone output (CZ-AP)-   reaction zone (CZ-B)-   reaction zone output (CZ-BP)-   cooling zone (CZ-C)-   cooling zone output (CZ-CP)-   quench zone (CZ-D)-   quench zone output (CZ-DP)-   restriction orifice differential pressure sensor (DP-AB)-   combined hydrocarbon connection (CZC0)-   combined hydrocarbon (CZC1)-   combined hydrocarbon input (CZC2)-   freeboard zone (FB-A)-   freeboard zone (FB-B)-   auxiliary heat exchanger (HX-2)-   Primary Gas Clean Up Heat Exchanger (HX-4)-   first reactor heat exchanger (HX-A)-   first reactor first heat exchanger (HX-A1)-   first reactor second heat exchanger (HX-A2)-   first reactor third heat exchanger (HX-A3)-   first reactor fourth heat exchanger (HX-A4)-   second reactor heat exchanger (HX-B)-   third reactor heat exchanger (HX-C)-   Feedstock Delivery System CO2 Heat Exchanger (HX-2000)-   classifier interior (INA,INB)-   fluid bed level (L-A)-   fluid bed level (L-B)-   first reactor pressure (P-A)-   second reactor pressure (P-B)-   third reactor pressure (P-C)-   third reactor steam drum pressure (P-C1)-   first quadrant (Q1)-   second quadrant (Q2)-   third quadrant (Q3)-   fourth quadrant (Q4)-   restriction orifice (RO-B)-   Refinery Superstructure System (RSS)-   third reactor heat transfer medium inlet temperature (T0)-   second reactor heat transfer medium inlet temperature (T1)-   second reactor heat transfer medium outlet temperature (T2)-   first reactor reactant temperature (TR1)-   first reactor heat exchanger fuel inlet temperature (T3)-   first reactor first heat exchanger fuel inlet temperature (T3A)-   first reactor second heat exchanger fuel inlet temperature (T3B)-   first reactor third heat exchanger fuel inlet temperature (T3C)-   first reactor fourth heat exchanger fuel inlet temperature (T3D)-   first reactor heat exchanger combined combustion stream outlet    temperature (T4)-   first reactor first heat exchanger combustion stream outlet    temperature (T4A)-   first reactor second heat exchanger combustion stream outlet    temperature (T4B)-   first reactor third heat exchanger combustion stream outlet    temperature (T4C)-   first reactor fourth heat exchanger combustion stream outlet    temperature (T4D)-   first reactor auxiliary heat exchanger combustion stream outlet    temperature (T5)-   first reactor auxiliary heat exchanger heat transfer medium inlet    temperature (T6)-   first reactor auxiliary heat exchanger heat transfer medium outlet    temperature (T7)-   HX-4 heat transfer medium inlet temperature (T8)-   HX-4 heat transfer medium outlet temperature (T9)-   first reactor temperature (T-A)-   second reactor temperature (T-B)-   third reactor temperature (T-C)-   first reactor dense bed zone reactant valve (VA1)-   first reactor dense bed zone reactant valve controller (CA1)-   first reactor dense bed zone reactant valve signal (XA1)-   first reactor dense bed zone oxygen-containing gas valve (VA2)-   first reactor dense bed zone oxygen-containing gas valve controller    (CA2)-   first reactor dense bed zone oxygen-containing gas valve signal    (XA2)-   first reactor feed zone reactant valve (VA3)-   first reactor feed zone reactant valve controller (CA3)-   first reactor feed zone reactant valve signal (XA3)-   first reactor feed zone oxygen-containing gas valve (VA4)-   first reactor feed zone oxygen-containing gas valve controller (CA4)-   first reactor feed zone oxygen-containing gas valve signal (XA4)-   first reactor splash zone reactant valve (VA5)-   first reactor splash zone reactant valve controller (CA5)-   first reactor splash zone reactant valve signal (XA5)-   first reactor splash zone oxygen-containing gas valve (VA6)-   first reactor splash zone oxygen-containing gas valve controller    (CA6)-   first reactor splash zone oxygen-containing gas valve signal (XA6)-   second reactor heat transfer medium supply valve (VB0)-   second reactor heat transfer medium supply valve controller (CB0)-   second reactor heat transfer medium supply valve signal (XB0)-   second reactor dense bed zone reactant valve (VB1)-   second reactor dense bed zone reactant valve controller (CB1)-   second reactor dense bed zone reactant valve signal (XB1)-   second reactor dense bed zone oxygen-containing gas valve (VB2)-   second reactor dense bed zone oxygen-containing gas valve controller    (CB2)-   second reactor dense bed zone oxygen-containing gas valve signal    (XB2)-   second reactor feed zone reactant valve (VB3)-   second reactor feed zone reactant valve controller (CB3)-   second reactor feed zone reactant valve signal (XB3)-   second reactor feed zone oxygen-containing gas valve (VB4)-   second reactor feed zone oxygen-containing gas valve controller    (CB4)-   second reactor feed zone oxygen-containing gas valve signal (XB4)-   second reactor splash zone reactant valve (VB5)-   second reactor splash zone reactant valve controller (CB5)-   second reactor splash zone reactant valve signal (XB5)-   second reactor splash zone oxygen-containing gas valve (VB6)-   second reactor splash zone oxygen-containing gas valve controller    (CB6)-   second reactor splash zone oxygen-containing gas valve signal (XB6)-   second reactor hydrocarbon valve (VB7)-   second reactor hydrocarbon valve controller (CB7)-   second reactor hydrocarbon valve signal (XB7)-   first hydrocarbon valve (VC1)-   first hydrocarbon valve controller (CC1)-   first hydrocarbon valve signal (XC1)-   third reactor oxygen-containing gas valve (VC2)-   third reactor oxygen-containing gas valve controller (CC2)-   third reactor oxygen-containing gas valve signal (XC2)-   second hydrocarbon valve (VC3)-   second hydrocarbon valve controller (CC3)-   second hydrocarbon valve signal (XC3)-   third hydrocarbon valve (VC4)-   third hydrocarbon valve controller (CC4)-   third hydrocarbon valve signal (XC4)-   third reactor heat transfer medium valve (VC5)-   third reactor heat transfer medium valve controller (CC5)-   third reactor heat transfer medium valve signal (XC5)-   mass sensor (WT1)-   mass sensor signal (WT1)-   connection (X1)-   connection (X2)-   connection (X3)-   connection (X4)-   connection (X5)-   connection (X6)-   connection (X7)-   connection (X8)-   connection (X0)-   connection (Y0)-   first reactor feed zone cross-sectional view (XAZ-B)-   first reactor splash zone cross-sectional view (XAZ-C)-   second reactor feed zone cross-sectional view (XBZ-B)-   second reactor splash zone cross-sectional view (XBZ-C)-   particulate classification chamber (A1A,A1B)-   particulate classification chamber (B1)-   bed material & inert feedstock contaminant mixture output (A2A,A2AA)-   bed material & inert feedstock contaminant mixture output (B2)-   bed material & inert feedstock contaminant mixture transfer conduit    (A3A,A3AA)-   bed material & inert feedstock contaminant mixture transfer conduit    (B3)-   bed material & inert feedstock contaminant mixture (A4A,A4AA)-   bed material & inert feedstock contaminant mixture (B4)-   bed material & inert feedstock contaminant mixture input (A5A,A5AA)-   bed material & inert feedstock contaminant mixture input (B5)-   classifier gas input (A6A,A6AA)-   classifier gas input (B6)-   classified recycled bed material output (A7A,A7AA)-   classified recycled bed material output (B7)-   classifier depressurization gas output (A8A,A8AA)-   classifier depressurization gas output (B8)-   classifier gas (A16,A16A)-   classifier gas (B16)-   classifier riser (A17,A17A)-   classifier riser (B17)-   classifier depressurization gas (A18,A18A)-   classifier depressurization gas (B18)-   classified inert feedstock contaminants (A19,A19A)-   classified inert feedstock contaminants (B19)-   classified recycled bed material input (A27,A27A)-   classified recycled bed material input (B27)-   classified recycled bed material (A37,A37A)-   classified recycled bed material (B37)-   classifier inert feedstock contaminant output (A9A,A9AA)-   classifier inert feedstock contaminant output (B9)-   mixture transfer valve (V9,V9A,V9AA)-   mixture transfer valve controller (C9A,C9AA)-   mixture transfer valve (V9B)-   classification gas transfer valve (V10,V10A,V10AA)-   classification gas transfer valve controller (C10A,C10AA)-   classification gas transfer valve (V10B)-   bed material riser recycle transfer valve (V11,V11A,V11AA)-   bed material riser recycle transfer valve controller (C11A,C11AA)-   bed material riser recycle transfer valve (V11B)-   depressurization vent valve (V12,V12A,V12AA)-   depressurization vent valve controller (C12A,C12AA)-   depressurization vent valve (V12B)-   inert feedstock contaminant drain valve (V13,V13A,V13AA)-   inert feedstock contaminant drain valve controller (C13A,C13AA)-   inert feedstock contaminant drain valve (V13B)-   classifier zone (INA1)-   gas distribution zone (INA2)-   gas distributor valve (V91)-   gas distributor valve controller (C91)-   large objects drain valve (V92)-   processor (PROC)-   memory (MEM)-   input/output interface (I/O)-   code (CODE)-   catalyst (CAT)

1.-7. (canceled)
 8. A municipal solid waste (MSW) energy recovery systemfor converting MSW containing inert feedstock contaminants, into aproduct gas (122), the system comprising: (a) a first reactor (100)comprising: a first reactor interior (101) suitable for accommodating abed material and endothermically reacting MSW in the presence of steamto produce product gas; a first reactor carbonaceous material input(104) for introducing MSW into the first reactor interior (101); a firstreactor reactant input (108) for introducing steam into the firstinterior (101); a first reactor product gas output (124) through whichproduct gas is removed; a classified recycled bed material input (A27,A27A) in fluid communication with an upper portion of the first reactorinterior (101); a particulate output (A2A) connected to a lower portionof the first reactor interior, and through which a mixture of bedmaterial and unreacted inert feedstock contaminants selectively exitsthe first reactor interior; and (b) a plurality of particulateclassification vessels (A1A, A1B) in fluid communication with the firstreactor interior, each vessel comprising: (i) a mixture input (A5A,A5AA) connected to the particulate output (A2A, A2AA), for receivingsaid mixture from the first reactor interior; (ii) a classifier gasinput (A6A, A6AA) connected to a source of classifier gas (A16A, 16AA),for receiving classifier gas to promote separation of said bed materialfrom said unreacted inert feedstock contaminants within said vessel;(iii) a bed material output (A7A, A7AA) connected to the classifiedrecycled bed material input (A27, A27A) of the first reactor interior(101) via a classifier riser conduit (A17, A17A), for returning bedmaterial separated from said mixture to the first reactor interior; and(iv) a contaminant output (A9A, A9AA) for removing unreacted inertfeedstock contaminants (A19A, 19AA) which have been separated from saidmixture, within the vessel.
 9. The system according to claim 8, furthercomprising: a mixture transfer valve (V9A, V9AA) positioned between theparticulate output (A2A, A2AA) and the mixture input (A5A, A5AA), toselectively control transfer of said mixture from the first reactor tothe vessel; a classification gas transfer valve (V10A, 10AA) positionedbetween the source of classifier gas (A16A, 16AA) and the classifier gasinput (A6A, A6AA), to selectively provide said classifier gas to thevessel; a bed material riser recycle transfer valve (V11A,V11AA)positioned between the bed material output (A7A, A7AA) and theclassified recycled bed material input (A27, A27A), to selectivelyreturn bed material separated from said mixture, to the first reactorinterior; and an inert feedstock contaminant drain valve (V13A, V13AA)configured to selectively remove unreacted inert feedstock contaminants(A19A, 19AA) which have been separated from said mixture.
 10. The systemaccording to claim 9, wherein: each vessel further comprises aclassifier depressurization gas output (A8A, A8AA); and adepressurization vent valve (V12A, V12AA) connected to the classifierdepressurization gas output (A8A, A8AA) to selectively vent the vessel.11. The system according to claim 10, further comprising: a mastercontroller configured to operate the system in any one of a plurality ofstates, including: a first state in which all of said valves are closed;a second state in which the mixture transfer valve (V9A, V9AA) is openand the remainder of said valves are closed, to allow said mixture toenter the vessel; a third state in which the classification gas transfervalve (V10A,V10AA) and the bed material riser recycle transfer valve(V11A,V11AA) are open and the remainder of said valves are closed, topromote separation of said bed material from said mixture and recyclingof separated bed material back into the first reactor; a fourth state inwhich the depressurization vent valve (V12A, V12AA) is open and theremainder of said valves are closed, to allow the vessel to vent; and afifth state in which the inert feedstock contaminant drain valve (V13A,V13AA) is open and the remainder of said valves are closed, to removeunreacted inert feedstock contaminants from the vessel.
 12. The systemaccording to claim 10, wherein the classifier gas is carbon dioxide. 13.The system according to claim 12, wherein: the product gas (122)comprises carbon dioxide; and a first portion of the carbon dioxide inthe product gas (122) is introduced into the vessel as the classifiergas.
 14. The system according to claim 10, wherein: the inert feedstockcontaminants comprise a plurality of different Geldart Group D solids;and the Geldart Group D solids comprise whole units and/or fragments ofone or more of the group consisting of allen wrenches, ball bearings,batteries, bolts, bottle caps, broaches, bushings, buttons, cable,cement, chains, clips, coins, computer hard drive shreds, door hinges,door knobs, drill bits, drill bushings, drywall anchors, electricalcomponents, electrical plugs, eye bolts, fabric snaps, fasteners, fishhooks, flash drives, fuses, gears, glass, gravel, grommets, hose clamps,hose fittings, jewelry, key chains, key stock, lathe blades, light bulbbases, magnets, metal audio-visual components, metal brackets, metalshards, metal surgical supplies, mirror shreds, nails, needles, nuts,pins, pipe fittings, pushpins, razor blades, reamers, retaining rings,rivets, rocks, rods, router bits, saw blades, screws, sockets, springs,sprockets, staples, studs, syringes, USB connectors, washers, wire, wireconnectors, and zippers.
 15. The system according to claim 10, wherein:bed material separated from said mixture and returned to the firstreactor interior comprises Geldart Group A solids; and the Geldart GroupA solids comprise one or more of the group consisting of inert material,catalyst, sorbent, engineered particles and combinations thereof. 16.The system according to claim 15, wherein: the engineered particlescomprise one or more of the group consisting of alumina, zirconia, sand,olivine sand, limestone, dolomite, catalytic materials, microballoons,microspheres, and combinations thereof.
 17. The system according toclaim 10, wherein: the bed material separated from said mixture andreturned to the first reactor interior comprises Geldart Group B solids;and the Geldart Group B solids are one or more of group consisting ofinert material, catalyst, sorbent, and engineered particles.
 18. Thesystem according to claim 17, wherein: the engineered particles compriseone or more of the group consisting of alumina, zirconia, sand, olivinesand, limestone, dolomite, catalytic materials, microballoons,microspheres, and combinations thereof.
 19. The system according toclaim 10, wherein: the particulate heat transfer material (105) iscomprised of both Geldart Group A and B solids; and the Geldart Group Aand B solids together comprise one or more from the group consisting ofinert material, catalyst, sorbent, and engineered particles.
 20. Thesystem according to claim 19, wherein the engineered particles compriseone or more from the group consisting of alumina, zirconia, sand,olivine sand, limestone, dolomite, catalytic materials, microballoons,and microspheres.
 21. The system according to claim 10, wherein: thefirst reactor is operated at a temperature between 320° C. and about900° C. to endothermically react the MSW in the presence of steam toproduce product gas. 22.-23. (canceled)
 24. The system according toclaim 9, further comprising: a gas distributor valve (V91) is positionedto separate the classifier interior (INA) into a classifier zone (INA1)and a gas distribution zone (INA2).
 25. The system according to claim24, wherein: the gas distributor valve (V91) has perforations so as topermit the valve to be in the closed position and still allow (a)classifier gas (A16) to pass up through the valve (V91), and (b) inertfeedstock contaminants and bed material to not pass down through thevalve.
 26. The system of claim 25, wherein perforations in the gasdistributor valve (V91) range from about 10 to about 100 microns. 27.The system according to claim 25, further comprising: a mastercontroller configured to operate the system in any one of a plurality ofstates, including: a first state in which the mixture transfer valve(V9A), gas distributor valve (V91), classification gas transfer valve(V10A), bed material riser recycle transfer valve (V11A), and inertfeedstock contaminant drain valve (V13A) are closed; a second state inwhich the mixture transfer valve (V9A) is open and the remainder of saidvalves are closed, to allow said mixture to enter the vessel; a thirdstate in which the classification gas transfer valve (V10A) and the bedmaterial riser recycle transfer valve (V11A) are open and the remainderof said valves are closed, to promote separation of said bed materialfrom said mixture and recycling of separated bed material back into thefirst reactor; a fourth state in which the depressurization vent valve(V12A) is open and the remainder of said valves are closed, to allow thevessel to vent; and a fifth state in which the gas distributor valve(V91) and inert feedstock contaminant drain valve (V13A) are open andthe remainder of said valves are closed, to remove unreacted inertfeedstock contaminants from the vessel.